Formable light weight composite material systems and methods

ABSTRACT

The present invention relates to filled polymeric materials including a polymer and a mass of metallic fibers distributed within the polymer, and to light weight composites which comprise at least a pair of metallic layers and a polymeric layer interposed between the pair of metallic layers, the polymeric layer containing the filled polymeric material. The composite materials of the present invention may be formed using conventional stamping equipment at ambient temperatures. Composite materials of the present invention may also be capable of being welded to other metal materials using a resistance welding process such as resistance spot welding. Preferred composite materials include one or any combination of the following features: metallic fibers that are ribbon fibers; a polymer selected from a polyolefin, a polyamide, or a combination thereof; or a metallic layer (e.g., one or both of the pair of metallic layers) having a surface facing the filled polymeric material that is untreated.

CLAIM OF BENEFIT OF FILING DATE

The present invention is a continuation of U.S. patent application Ser.No. 13/027,423, filed on Feb. 15, 2011, which claims the benefit of thefiling date of U.S. Provisional Patent Application Nos. 61/304,640(filed by Mizrahi et al. on Feb. 15, 2010), 61/371,360 (filed by Mizrahiet al. on Aug. 6, 2010), 61/377,599 (filed by Mizrahi on Aug. 27, 2010),and 61/387,164 (filed by Mizrahi on Sep. 28, 2010), the contents ofwhich are hereby incorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates generally to fiber-filled polymericmaterials, and to composite materials that include a layer of thefiber-filled polymeric material, and more particularly to sandwichcomposites that include a layer of the fiber-filled polymeric materialand a metallic layer.

BACKGROUND

In International Patent Application Publication WO 2010/021899(published on Feb. 25, 2010 by Mizrahi, and incorporated herein byreference in its entirety), there are described unique and new lightweight composite materials and associated methods and systems. Suchcomposites have widespread application across a range of technologies.For example, it is described as having particular application as atransportation technology (e.g., an automotive technology). It may alsohave other applications, such as a construction technology or as anappliance technology. Unfortunately cost and performance requirementsvary from technological field to technological field, or even betweendifferent applications within a technological field, so the ability tohave a “one size fits all” material system is a difficult proposition.Accordingly, notwithstanding the various teachings of InternationalPatent Application Publication WO 2010/021899, it is still attractive toexplore variations in material systems, for enhancing the commercialattractiveness of composite materials, such as sandwich type compositelaminates. Moreover, for some applications it may be attractive to tunethe performance of various composite materials, such as the materials ofWO 2010/021899, so that they have relatively broad processing windows,so that they exhibit weldability, so that they exhibit drawability, sothat they can be coated, and/or so that they otherwise can take theplace of conventional materials (e.g., steel) for various applications,and at the same time provide appreciable weight savings relative to theconventional material. By way of example, in the transportation industrythere remains a need for relatively lightweight materials alternative tosteel, aluminum or both for vehicle components (such as panels, supportmembers or the like).

SUMMARY OF THE INVENTION

The present teachings are directed to sandwich laminate materialsystems. In one particular aspect, the teachings find particularapplication as an improved automotive technology system that can be usedin combination with, or even as a substitute for many of the traditionalmetal applications, while affording potentially substantial weightsavings (e.g., at least about 10%, 20%, 30% or more as compared with thesame application in which a conventional material (e.g., steel) isordinarily used. As will be appreciated, while the teachings emphasizeuse in automotive technologies, they find use in others.

In general, the teachings herein pertain to a filled polymeric material(and composites such as sandwich composites that incorporate the filledpolymeric material), comprising: a thermoplastic polymer, thethermoplastic polymer selected from the group consisting of apolyolefin, an acetal copolymer, a polyamide, a polyamide copolymer(such as a polyamide copolymer including at least two amide monomersand/or a polyamide copolymer including at least one monomer that is notan amide), an ionomer, a polyimide, a polyester, a polycarbonate, athermoplastic polyurethane, a thermoplastic polyether-ester copolymer,an acrylonitrile butadiene styrene copolymer, a polystyrene, a copolymerincluding at least 60 wt. % of an α-olefin and at least one additionalmonomer, other copolymers including any of these polymers, ionomersincluding any of these polymers, and any combination thereof; and aplurality of metallic fibers distributed within the polymer, wherein themetallic fibers are present at a concentration greater than about 3% byvolume, based on the total volume of the filled polymeric material.

This aspect of the teachings may be further characterized by one of anycombination of the following: the thermoplastic material includes apolyolefin (e.g., polypropylene, polyethylene or a combination thereof),an acetal copolymer, a polyamide, a polyamide copolymer, a polyimide, apolyester, a polycarbonate, an acrylonitrile butadiene styrenecopolymer, a polystyrene, a copolymer including at least 60 wt. % of anα-olefin and at least one additional monomer, copolymers including anyof these polymers, or any combination thereof; the thermoplasticmaterial includes a polyamide copolymer, a thermoplastic polyurethane, athermoplastic polyether-ester copolymer, an ionomer, or any combinationthereof; the filled polymeric material has a thickness, the fibers arepresent as a mass of fibers, and the mass of fibers spans the thicknessof filled polymeric material; or the thermoplastic material has anelongation at failure of at least about 20% at a tensile strain rate ofabout 0.1 s⁻¹ as measured according to ASTM D638-08.

In one particular aspect of this teaching the polymer may be a polymerselected from a polyolefin, a polyamide, or a combination thereof; thefibers may be in the form of a mass (e.g., an entangled mass) thatincludes ribbons, such as steel ribbons.

Another aspect of the teachings is directed at a light weight compositecomprising: a first metallic layer (e.g., sheet steel); a secondmetallic layer (e.g., sheet steel); a polymeric layer (e.g., a polymeras described in the above aspects of the teachings) disposed between thefirst metallic layer and the second metallic layer; and a plurality ofmetallic fibers distributed within the polymeric layer; wherein thefraction of the metallic fibers that contact a metallic layer along atleast half of the length of the fiver is about 0.3 or less; and thepolymeric layer includes a filled polymeric material containing apolymer, the polymer having an elongation at failure of at least about20% at a tensile strain rate of about 0.1 s⁻¹ as measured according toASTM D638-08; so that the resulting composite material may be welded,and so that the resulting composite may be plastically deformed atstrain rates greater than about 0.1 s⁻¹. As to this aspect of theteachings, the first metallic layer, the second metallic layer, or bothmay be free of any surface treatment, coating or other layer disposedbetween it and the polymeric layer (it being appreciated that optionallyone or more suitable layers may nonetheless be employed and still bewithin the general teachings herein).

A method related aspect of the invention is directed at a process offorming a sheet comprising: forming a sheet of a filled thermoplasticpolymer as described herein, and monitoring the quality of the sheet.For example, the polymeric layer may be preformed (e.g., as a sheet) andlaminated to at least one metallic layer or between opposing metalliclayers, such as in a continuous process, a batch process or otherwise.

Still another aspect of the teachings is directed at a process offorming a composite part comprising a step of stamping a compositematerial, such as described herein.

A further aspect of the teachings is directed at a welded structureincluding a composite material, such as a composite material describedherein, welded to steel (e.g., resistance welded), to a metal other thansteel, to a substantially identical composite material, to a differentcomposite material, or any combination thereof. Surprisingly, the lightweight composite material may have a polymeric layer including aquantity and an arrangement of metallic fibers sufficient to allowelectrical conductivity so that the composite material is capable ofbeing welded (e.g., using conventional equipment and processes of a typeused for resistance welding steel in existing vehicle production lines),and yet sufficiently low so that the composite material affordsattractive performance characteristics such as a relatively highstrength to weight ratio, coatability, reducing the transmission ofsound through the material or any combination thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a composite material having a polymeric layer and ametallic layer.

FIG. 1B illustrates a composite material having a polymeric core layerinterposed between two metallic layers.

FIG. 2 is a diagram of an illustrative process for monitoring apolymeric material or a composite material.

DETAILED DESCRIPTION

In general, the materials herein employ a filled polymeric material, aswill be described, and particularly one that includes a metal fiberphase distributed in a polymeric matrix. In general, the compositematerials herein employ at least two layers, one of which is the abovefilled (e.g., fiber-filled) polymeric material (e.g., in a fiber-filledpolymeric layer). More particularly, the materials herein are compositesthat include a sandwich structure, pursuant to which a fiber-filledpolymeric layer is sandwiched between two or more other layers. Thematerials herein also contemplate sandwich structure pre-cursors, e.g.,a first layer upon which a filled polymeric layer is attached so thatthe filled polymeric layer has an exposed outer surface. A second layermay subsequently be attached to the filled polymeric layer. Theinvention also contemplates feedstock compositions (e.g., in the form ofa pellet, a sheet, or otherwise) that include a fiber-filled polymericmaterial in accordance with the present teachings. As will beillustrated, the materials herein exhibit a unique, surprising, andattractive combination of properties, which render the materialssuitable for deforming operations (e.g., relatively high strain rateforming operations, such as stamping), welding operations, or both. Forinstance, as will be seen from the teachings, the filled polymeric layeris designed in a manner such that is multiphasic. At least one phase(e.g., the filler) provides a conductive flow path, and Is such that itis plastically deformable, and may even strain harden when subjected toa stress that induces plastic deformation. In addition, the polymericphase is such that it bonds sufficiently to another material (e.g., ametal layer such as a steel sheet) that processing of the compositematerials for welding and/or deforming (e.g., forming, such as bystamping), will be free of delamination of the composite. The polymericphase may also be such that it withstands degradation when subjected tocoating operations (e.g., when subjected to chemical baths such aselectrostatic coating baths, or other baths for imparting corrosionresistance, common in sheet metal coating operations).

The present teachings in their various aspects make use of uniquecombinations of materials to derive an attractive composite, andparticularly a laminate composite. By way of example, withoutlimitation, the laminate may be drawn (e.g., deep drawn), welded, orboth, in a manner similar to conventional art-disclosed sheet materials,such as sheet metal (e.g., stainless and/or low carbon steel). Ingeneral, the invention makes use of a multi-phase composite material inwhich the materials are selected and employed so that, as a whole, theyimpart drawability, weldability, or both. Additionally, the materialsare such that the resulting laminates can be processed in a mannersimilar to conventional art-disclosed thin walled structuresparticularly as it relates to processes for imparting a decorative orfunctional surface treatment (e.g., a coating, a plating, or otherwise).

For example, a particular preferred combination of materials herein mayinclude two layers that flank a core material, the latter of which ispreferably a filled polymeric material. The filled polymeric materialpreferably includes at least one polymer, which polymer may include,consist essentially of, or consist entirely of a thermoplastic polymer,or otherwise has characteristics that render it generally processable asa thermoplastic polymer. The filled polymeric material preferably alsoincludes a filler phase, and preferably a phase having a filler thatincludes, consists essentially of, or consists entirely of a fiberphase, and particularly an elongated fiber phase, such as an elongatedmetal fiber phase. Such phase may be sufficiently positioned and/ordistributed (e.g., wrapped, braided, aligned, entangled, or anycombination thereof), and used in sufficient volume that an electricallyconductive network across at least portions of the filled polymericmaterial is realized even if the polymer itself generally is notconductive. A particularly preferred elongated fibrous phase may alsoitself exhibit elongation (either or both individual fibers or the massas a whole) and possibly strain hardening.

It should be appreciated that references to “layers” herein do notnecessarily require discrete and separate pieces of material. Forexample, a layered composite may still be within the teachings herein ifit includes a single sheet of a material that has been folded over uponitself to define two layers of the material, albeit sharing a commonedge, between which is located the filled polymeric material.

Turning now with more particularity to the teachings herein, it is seenthat in a first aspect there is contemplated a composite material thatis made from layers of adjoining dissimilar materials, which includes atleast one layer (e.g., a metal layer such as a metal face layer) and atleast one polymeric layer, the composite being formable (e.g., stampableby application of a stress to cause plastic strain (e.g., at arelatively rapid rate) of the material or otherwise capable of beingcold-formed on a press machine) into a formed panel. The compositematerial may be a composite laminate containing one metallic layer andone polymeric layer, or it may include one or more other layers. Forexample, it may be a laminate including one metallic layer interposedbetween two polymeric layers, or a laminate including a polymeric layersandwiched between at least two opposing metallic layers. As indicated,a particularly preferred approach envisions this latter structure, theformer structures possibly serving as precursors for the laterstructure. In such instance the method of forming a sandwich structuremay include a step of applying a layer to a precursor to form a sandwichstructure, a step of applying a first precursor to a second precursor toform a sandwich structure, or both.

An example of a composite laminate 10 having one metallic layer 14 andone polymeric layer 16 is illustrated in FIG. 1A. A sandwich 12 maycontain a first metallic layer 14, a second metallic layer 14′ and apolymeric layer 16 (e.g., a polymeric core layer) interposed between thefirst and second metallic layers, as illustrated in FIG. 1B. Referringto FIGS. 1A and 1B, the polymeric layer 16 includes at least one polymer(e.g., a thermoplastic polymer) 18 and a fiber 20. The polymeric layer16 and the first metallic layer 14 may have a common surface 22. Asillustrated in FIGS. 1A and 1B some or all of the fibers may have alength and orientation such that they extend from one surface of thepolymeric layer to the opposing surface of the polymeric layer. However,it will be appreciated that other fiber lengths and orientations arewithin the scope of the inventions. For example, the fraction of thefibers (e.g., metallic fibers) that extend between the two opposingfaces of the polymeric layer may be less than 20%, less than 10%, lessthan 5%, or less than 1%. The fibers illustrated in FIGS. 1A and 1B aregenerally straight fibers. It will be appreciated from the teachingsherein that preferred fibers are generally not straight. Preferredfibers have one or more bends along a length of the fiber, have agenerally curved profile, or both.

As mentioned, in addition to the composite, multi-layered structures,another aspect of the invention contemplates a precursor polymeric layersheet material (i.e., a single layer of the polymeric layer) includingthe thermoplastic polymer and the fiber (e.g., metallic fiber), that canbe later sandwiched between two metallic layers.

Yet another aspect of the invention contemplates a precursor polymericfeedstock material containing the polymer and the fibers. Such apolymeric feedstock material may be formed (e.g., molded or extruded)into the polymeric layer (e.g., into a sheet) either as a singlematerial or by diluting with one or more additional materials (e.g., oneor more additional polymers). As such, the precursor polymeric feedstockmaterial may include some or all of the components in the polymericlayer of the composite material. Preferably, the precursor polymericfeedstock material includes substantially all of the fiber for thepolymeric layer.

In use, the composites may be deformed (e.g., formed, such as bystamping), attached to another structure (e.g., to steel or to anothercomposite material), or both. A preferred approach is to employ a stepof welding the composite of the invention to the other structure. Theformed panel may be joined to other parts, when necessary, by techniquesother than welding, such as by using adhesives, a brazing process, orthe like. In both cases, the composite material (e.g., the laminate orsandwich sheet) is formable by low-cost stamping methods and yet issurprisingly free of the limitations that have been faced previously inthe art. The unique features of the composite material render it anextremely attractive candidate for applications which traditionallyutilize a regular monolithic metal sheet, such as in the body panelscurrently employed in the transportation (e.g., automotive) industry.

One unique feature of the invention is that it includes specificselection of the polymer (e.g., thermoplastic polymer) and the metalfibers, and incorporation of metal fibers and optional particles, aswell as other optional fillers, into the polymeric matrix to produce anovel formable composite material (e.g. sandwich or laminate structure)for low-cost stamping operation. Another novelty is that the stampablesandwiches can be joined by conventional welding techniques such asresistance welding (e.g., spot welding, seam welding, flash welding,projection welding, or upset welding), energy beam welding (e.g., laserbeam, electron beam, or laser hybrid welding), gas welding (e.g.,oxyfuel welding, using a gas such as oxyacetylene), arc welding (e.g.,gas metal arc welding, metal inert gas welding, or shielded metal arcwelding). Preferred joining techniques include high speed weldingtechniques such as resistance spot welding and laser welding.

Various features of formable/stampable materials, test methods, testcriteria, descriptions of defects, welding processes andcharacteristics, and descriptions of forming processes are described inthe following publications, all expressly incorporated herein byreference:

-   M. Weiss, M. E. Dingle, B. F. Rolfe, and P. D. Hodgson, “The    Influence of Temperature on the Forming Behavior of Metal/Polymer    Laminates in Sheet Metal Forming”, Journal of Engineering Materials    and Technology, October 2007, Volume 129, Issue 4, pp. 530-537.-   D. Mohr and G. Straza, “Development of Formable All-Metal Sandwich    Sheets for Automotive Applications”, Advanced Engineering Materials,    Volume 7 No. 4, 2005, pp. 243-246.-   J. K. Kim and T. X. Yu, “Forming And Failure Behaviour Of Coated,    Laminated And Sandwiched Sheet Metals: A Review”, Journal of    Materials Processing Technology, Volume 63, No 1-3, 1997, pp. 33-42.-   K. J. Kim, D. Kim, S. H. Choi, K. Chung, K. S. Shin, F.    Barlat, K. H. Oh, J. R. Youn, “Formability of    AA5182/polypropylene/AA5182 Sandwich Sheet, Journal of Materials    Processing Technology, Volume 139, Number 1, 20 Aug. 2003, pp. 1-7.-   Trevor William Clyne and Athina Markaki U.S. Pat. No. 6,764,772    (filed Oct. 31, 2001, issued Jul. 20, 2004).-   Frank Gissinger and Thierry Gheysens, U.S. Pat. No. 5,347,099, Filed    Mar. 4, 1993, Issued Sep. 13, 1994, “Method And Device For The    Electric Welding Of Sheets Of Multilayer Structure”.-   Straza George C P, International Patent Application Publication    (PCT): WO2007062061, “Formed Metal Core Sandwich Structure And    Method And System For Making Same”, Publication date: May 31, 2007.-   Haward R. N., Strain Hardening of Thermoplastics, Macromolecules    1993, 26, 5860-5869.-   Intemational Patent Application Publication WO 2010/021899    (published on Feb. 25, 2010 by Mizrahi).-   U.S. Patent Application Nos. 61/290,384 (filed on Dec. 28, 2009 by    Mizrahi), 61/089,704 (filed on Aug. 18, 2008 by Mizrahi), 61/181,511    (filed on May 27, 2009 by Mizrahi), Ser. No. 12/540,771 (filed on    Aug. 13, 2009 by Mizrahi), 61/290,384 (filed on Dec. 28, 2009 by    Mizrahi), and Ser. No. 12/978,974 (filed on Dec. 27, 2010 by    Mizrahi).    Materials

By way of example, the use of a fibrous filler (and in one particularaspect, a ribbon fiber filler) in the polymeric layer is believed tofacilitate composite manufacturing and surprisingly low levels may beemployed to achieve the beneficial results herein. Surprisingly, theselection and combination of materials taught herein affords the abilityto employ less metal per unit volume than conventional metal structuresof like form (e.g., sheet metal) while still exhibiting comparableproperties and characteristics. The problem that the skilled artisanmight envision in such a combination of materials unexpectedly areavoided. In this regard, some of the behavioral characteristics of thematerials that might be predicted are surprisingly avoided, are employedadvantageously in the resulting composite, or both. The resultinglaminates thus render themselves as attractive candidates to be adrop-in substitute for existing materials, for example, they can beemployed instead of sheet steel, at substantial weight savings ascompared with steel, without the need for significant investment inresources to re-tool or significantly alter processing conditions.

Polymeric Layer

The polymeric layer generally may include or even consist essentially ofa filled polymer, (e.g., a thermoplastic polymer filled with a mass ofreinforcing fibers, such as a mass of metallic fibers, and moreparticularly a mass including steel ribbon fiber components).

The filled polymeric material for use in the polymeric layer preferablyis one that generally would be characterized as being relatively rigid,relatively strong, have a relatively high elongation at break, have highstrain hardening properties, is light weight, or any combinationthereof, such as described in International Patent ApplicationPublication WO 2010/021899 (published on Feb. 25, 2010 by Mizrahi),incorporated herein by reference in its entirety (see for exampleparagraphs 015-022, 029-051, and 085-091).

Preferably, at least some of the polymer in the filled polymericmaterial is a thermoplastic, but it may be or include a thermosetpolymer, particularly a thermoset polymer that is processable as athermoplastic, but cured. Preferably, at least 50% (more preferably atleast 60%, 70%, 80%, 90% or even 95%, if not 100%) by weight of thepolymer used in the filled polymeric material is a thermoplasticpolymer.

The filled polymeric material may have electrical conductivityproperties (e.g., the filled polymeric material may be an electricalconductor) such that a conductive path is provided through the filledpolymer and the composite material may be welded to another structuresuch as a sheet metal. The electrical conductivity properties of thepolymeric core material may be achieved by employing metallic fibers andoptionally metallic or carbon black particles that are dispersed in thepolymer in a quantity to have at least a percolation concentration, suchas described in International Patent Application Publication WO2010/021899 (published on Feb. 25, 2010 by Mizrahi), see for exampleparagraphs 064-081 incorporated herein by reference. The filledpolymeric material and the composite materials of the present teachingsmay be weldable using art-disclosed welding processes (e.g., weldschedules) or with other welding processes (e.g., weld schedules) asdescribed in International Patent Application Publication WO 2010/021899(published on Feb. 25, 2010 by Mizrahi) (see for example paragraphs 15,20-22, 29-30, 37-39, 47, 109, and 112-117, incorporated herein byreference) and U.S. patent application Ser. No. 12/978,974 (filed onDec. 27, 2010 by Mizrahi) (see for example paragraphs 019-31, and034-042, and 055137, incorporated herein by reference). For example, thematerials may allow for more economical weld schedules that are faster,require less energy, or both.

The filled polymeric material (e.g., the polymer of the filled polymericmaterial) may additionally include one or more additives known to thepolymer compounding art, such as described in International PatentApplication Publication WO 2010/021899 (published on Feb. 25, 2010 byMizrahi). For example, the filled polymeric material may includehalogenated flame retardant compounds disclosed in U.S. Pat. No.3,784,509 (Dotson et. al., Jan. 8, 1974, see for example the substitutedimides described in column 1, line 59 through column 4, line 64), U.S.Pat. No. 3,868,388 (Dotson et al. Feb. 25, 1975, see for example thehalogenated bisimides described in column 1, line 23 through column 3,line 39); U.S. Pat. No. 3,903,109 (Dotson et al. Sep. 2, 1975, see forexample the substituted imides described in column 1, line 46 throughcolumn 4, line 50); U.S. Pat. No. 3,915,930 (Dotson et al. Oct. 28,1975, see for example halogenated bisimides described in column 1, line27 through column 3, line 40); and U.S. Pat. No. 3,953,397 (Dotson etal. Apr. 27, 1976, see for example the reaction products of a brominatedimide and a benzoyl chloride described in column 1, line 4 throughcolumn 2, line 28), each of which is incorporated by reference in itsentirety. The polymer, the filled polymeric material or both may includeone or more additives for improving the adhesion between the polymer anda surface of the metallic layer. The polymer, the filled polymericmaterial or both, may include one or more additives to improve thedrawing (e.g., stamping) of the composite material. The polymer, thefilled polymeric material or both may include one or more additives forcontrolling (e.g., increasing or decreasing) the shrinkage of the filledpolymeric material when the filled polymeric material is cooled from amelt state to a solid state. The polymer may be substantially free of,or entirely free of additives that reduce the adhesion between thepolymer and a metallic layer (e.g., a steel layer).

The filled polymeric material may be free of a plasticizer or otherrelatively low molecular weight materials which may become volatilized(e.g., during a resistance welding process). If employed, theconcentration of plasticizer or other relatively low molecular weightmaterials preferably is less than about 3 wt. %, more preferably lessthan about 0.5 wt. %, and most preferably less than about 0.1 wt. %based on the total weight of the filled polymeric material (e.g., suchthat the filled polymeric material does not delaminate from a metalliclayer).

It is also possible the teachings herein contemplate a step of selectingmaterials, processing conditions, or both, so that during processing,delamination of the filled polymeric material from the metallic layer issubstantially, or entirely avoided (e.g., delamination caused by vaporpressure buildup at an Interface between the filled polymeric materialand the metallic layer sufficient for causing delamination).

Polymers

With more attention now to particular examples of polymers for useherein, the polymers used for the filled polymeric material preferablyinclude thermoplastic polymers that either have a peak meltingtemperature (as measured according to ASTM D3418-08) or a glasstransition temperature (as measured according to ASTM D3418-08) greaterthan about 50° C. (preferably greater than about 80° C., even morepreferably greater than about 100° C., even more preferably greater thanabout 120° C. more preferably greater than about 160° C., even morepreferably greater than 180° C. and most preferably greater than about205° C.). The thermoplastic polymer may have a peak melting temperature,a glass transition temperature, or both that is less than about 300° C.,less than about 250° C., less than about 150° C., or even less thanabout 100° C. They may be at least partially crystalline at roomtemperature or substantially entirely glassy at room temperature.Suitable polymers (e.g., suitable thermoplastic polymers) may becharacterized by one or any combination of the following tensileproperties (measured according to ASTM D638-08 at a nominal strain rateof 0.1 s⁻¹); a tensile modulus (e.g., Young's Modulus) greater thanabout 30 MPa, (e.g., greater than about 750 MPa, or greater than about950 MPa); an engineering tensile strength (i.e., σ_(a)), a true tensilestrength (i.e., σ_(t), where σ_(t)=(1+ε_(e))σ_(e) where ε_(e) is theengineering strain), or both, greater than about 8 MPa (e.g., greaterthan about 25 MPa, greater than about 60 MPa, or even greater than about80 MPa); or a plastic extension at break or elongation at failure of atleast about 20% (e.g., at least about 50%, at least about 90%, or evenat least about 300%). Unless otherwise specified, the term tensilestrength refers to engineering tensile strength.

The polymer may preferably have strain hardening properties (e.g., arelatively high strain hardening modulus, a relatively low extrapolatedyield stress, or both), such as described in International PatentApplication Publication WO 2010/021899 (published on Feb. 25, 2010 byMizrahi), see for example paragraphs 052-063, incorporated herein byreference. As such, the strain hardening properties may be measuredusing the method of Haward R. N., Strain Hardening of Thermoplastics,Macromolecules 1993, 26, 5860-5869, incorporated herein by reference inits entirety.

Examples of thermoplastic polymers which may be used for the polymericlayer include polyolefins (e.g. polyethylene, polypropylene or both),acetal copolymers, polyamides, polyamide copolymers, polyimides,polyesters (e.g., polyethylene terephthalates and polybutyleneterephthalate), polycarbonates, thermoplastic polyurethanes,thermoplastic polyether-ester copolymers (such as a thermoplasticelastomer ether-ester material described in ASTM D 6835-08, incorporatedherein by reference), acrylonitrile butadiene styrene copolymers,polystyrenes, copolymers including at least 60 wt. % of an α-olefin andat least one additional monomer (such as an ethylene copolymersincluding at least 80 wt. % ethylene), copolymers including any of thesepolymers, ionomers including any of these polymers, blends of any ofthese polymers, or any combination thereof.

The thermoplastic polymer may include a polyolefin, such as a polyolefindescribed in paragraph 065 of U.S. Provisional Patent Application61/371,360 filed on Aug. 6, 2010, incorporated herein by reference. Thepolyolefin may be a homopolymer or a copolymer. The polyolefin mayinclude, consisting essentially of, or consisting entirely of one ormore α-olefins, such as one or more α-olefins having from about 2 toabout 10 carbon atoms.

Preferable polyolefins include polypropylene homopolymers (e.g.,isotactic polypropylene homopolymer), polypropylene copolymers (e.g.,random polypropylene copolymers, impact polypropylene copolymer, orother polypropylene copolymer containing isotactic polypropylene),polyethylene homopolymer (e.g., high density polyethylene, or otherpolyethylene having a density greater than about 0.94 g/cm³),polyethylene copolymers (e.g., preferably including at least about 60%ethylene, more preferably at least 80 wt. % ethylene), low densitypolyethylene, a blend of any of these polymers, or any combinationthereof. Polypropylene homopolymers and polypropylene copolymers may besubstantially free of atactic polypropylene. If present, theconcentration of atactic polypropylene in the polypropylene preferablyis less than about 10 wt. %. Without limitation, copolymers that may beemployed include copolymers (e.g., polypropylene copolymers orpolyethylene copolymers) that that consist essentially of (e.g., atleast 98% by weight), or consist entirely of one or more α-olefins. Morepreferred polyolefins include high density polyethylene (e.g., having adensity greater than about 0.945 g/cm³, such as from about 0.945 toabout 0.990 g/cm³ or from about 0.945 to about 0.960 g/cm³), low densitypolyethylene (e.g., a polyethylene having a sufficient concentration oflong chain branches, typically greater than about 15 carbon atoms long,so that its density is about 0.945 g/cm³ or less), linear low densitypolyethylene (e.g., a copolymer having a density of about 0.915 to about0.930 g/cm³), medium density polyethylene (e.g., a copolymer having adensity of about 0.930 to about 0.945 g/cm³), very low densitypolyethylene (e.g., having a density of about 0.900 to about 0.915g/cm³), polyethylene plastomers (e.g., a copolymer having a density ofabout 0.860 to about 0.900 g/cm³), isotactic polypropylene homopolymer,isotactic polypropylene copolymers (e.g., having a crystallinity ofabout 5 wt. % or more), impact polypropylene, polypropylene blockcopolymers including one or more blocks of isotactic polypropylene,mixtures thereof, or any combination thereof. Even more preferredpolyolefins include low density polyethylene, linear low densitypolyethylene, very low density polyethylene, or any combination thereof.Other polyolefins that may be used include copolymers of at least oneolefin and one or more monomers that is not an olefin. For example,other polyolefins that may be employed include copolymers that include,consist essentially of, or consist entirely of i) one or more α-olefins(e.g., at least 60 wt. % of an α-olefin) and ii) one or more polarcomonomers, such as a polar comonomer selected from the group consistingacrylates, (e.g., methyl acrylate, butyl acrylate, or both), vinylacetate, acrylic acids (e.g., acrylic acid, methacrylic acid, or both),methyl methacrylate, or any combination thereof. The concentration ofthe comonomer may be less than about 40 wt. %, preferably less thanabout 25 wt. %, more preferably less than about 20 wt. %, and mostpreferably less than about 15 wt. % based on the total weight of thecopolymer. Exemplary polyethylene copolymers that may be used includeethylene-co-vinyl acetate (i.e., “EVA”, for example containing less thanabout 20 wt. % vinyl acetate), ethylene-co-methyl acrylate (i.e., EMA),ethylene co-methacrylic acid, or any combination thereof. Exemplaryα-olefins that may be used in the copolymer include ethylene, propylene,butene, hexene, octene, or any combination thereof.

Polyamides useful in the present teachings may include polymers havingone or more repeating units that includes an amide groups along thebackbone of the polymer chain. For example, polyamides may be a reactionproducts of a diamine and a diacid. Other examples of polyamides includemonadic polyamides. Generally, monadic polyamides are formed by a ringopening reaction. Exemplary polyamides which are formed from a diamineand a diacid may include polyamides (e.g., nylons) containing reactionproducts of either adipic acid or terephthalic acid with a diamine.Exemplary monadic polyamides include nylon 6, and poly(p-benzamide). Thenylon may be a homopolymer, a copolymer, or a mixture thereof. Preferredpolyamide homopolymers which may be used in the present inventioninclude nylon 3, nylon 4, nylon 5, nylon 6, nylon 6T, nylon 66, nylon610, nylon 612, nylon 69, nylon 7, nylon 77, nylon 8, nylon 9, nylon 10,nylon 11, nylon 12, and nylon 91. Copolymers containing any of the abovementioned polyamides may also be used. Polyamide copolymers may berandom copolymers, block copolymers, a combination thereof. Examples ofpolyamide copolymers include polymers having a plurality of differentamides (i.e., a polyamide-polyamide copolymers), polyesteramidecopolymers, polyetheresteramide copolymers, polycarbonate-ester amides,or any combination thereof.

A polyamide-polyamide copolymer may include two or more of thepolyamides described herein for a polyamide homopolymer. Preferredpolyamide-polyamide copolymers include, polyamide 6 and polyamide 66,polyamide 610, or any combination thereof. For example, apolyamide-polyamide copolymer may consist essentially of two or morepolyamides selected from the group consisting of polyamide 6, polyamide66, polyamide 69, polyamide 610, polyamide 612, and polyamide 12. Morepreferably the polyamide-polyamide copolymer consists essentially of twoor more polyamides selected from the group consisting of polyamide 6,polyamide 66, polyamide 69, and polyamide 610. Examples of suchcopolymers include polyamide 6/66, polyamide 6/69, and polyamide6/66/610. A particularly preferred polyamide-polyamide copolymer is apolyamide 6/66 copolymer. The concentration of polyamide 66 in thepolyamide 6/66 copolymer may be about 90 weight percent or less,preferably about 70 weight percent or less, more preferably about 60weight percent or less, and most preferably about 50 weight percent orless, based on the total weight of the copolymer. The concentration ofpolyamide 6 in the polyamide 6/66 copolymer may be about 10 weightpercent or more, preferably about 30 weight percent or more, morepreferably about 40 weight percent or more, and most preferably about 50weight percent or more, based on the total weight of the copolymer.Another particularly preferred polyamide-polyamide copolymer is a randomor block copolymer of a polyamide 6 and polyamide 69. Polyamidecopolymers (i.e., a copolymer including one or more amide monomers) mayinclude a polyether, such as an aliphatic ether or an aromatic ether.

Polyethers which may be used in a polyamide copolymer may be formed bythe polymerization of a diol, such as a glycol (e.g., with one or moreadditional monomers). Exemplary glycols which may be used includepropylene glycol, ethylene glycol, tetramethylene glycol, butyleneglycol, or any combination thereof. Any of the above copolymers may be ablock copolymer including a relatively soft block and a relatively hardblock. The ratio of the elastic modulus of the relatively hard block tothe relatively hard block may be greater than about 1.1, preferablygreater than about 2, and more preferably greater than about 10. Therelatively hard block may include or consist essentially of one or morearomatic amides, one or more semi-aromatic amides, or one or morealiphatic amides. The relatively soft block may include a polyester,such as a polyester described above (e.g., an aliphatic polyester), apolycarbonate (e.g., an aliphatic polycarbonate), a polyether (e.g., analiphatic polyether), or any combination thereof. Amide copolymers mayinclude a first monomer (e.g., a first amide monomer) and a secondmonomer, each both independently having a concentration greater thanabout 5 wt. %, preferably greater than about 20 wt. %, more preferablygreater than about 30 wt. % and most preferably greater than about 40wt. %, based on the total weight of the copolymer. The concentration ofthe first monomer, the second monomer, or both independently may be lessthan about 95 wt. %, preferably less than about 80 wt. %, morepreferably less than about 70 wt. %, and most preferably less than about60 wt. % based on the total weight of the copolymer. The combinedconcentration of the first monomer and the second monomer may be greaterthan about 50 wt. %, preferably greater than about 75 wt. %, morepreferably greater than 90 wt. %, and most preferably greater than about95 wt. % based on the total weight of the copolymer.

The polyamide copolymer may be characterized as a thermoplasticelastomer, having a relatively low melting temperature, a relatively lowelastic modulus, or both. For example, the copolymer may have arelatively low melting temperature compared to the highest meltingtemperature of any of the homopolymer consisting essentially of one ofthe monomers of the copolymer. For example, the copolymer may have arelatively low elastic modulus compared to the highest elastic modulusof any of homopolymer consisting essentially of one of the monomers ofthe copolymer. Preferred polyamide copolymers may be characterized by amelting point less than about 220° C. (preferably less than about 190°C., more preferably less than about 170° C., and most preferably lessthan about 150° C.) as measured according to ASTM D3418-08; a meltingpoint greater than about 60° C. (preferably greater than about 80° C.,more preferably greater than about 100° C., and most preferably lessthan about 110° C.) as measured according to ASTM D3418-08; an elasticmodulus less than about 2.5 GPa (preferably less than about 1.2 GPa,more preferably less than about 800 MPa, and most preferably less thanabout 500 MPa), as measured according to ASTM D638-08; an elasticmodulus greater than about 50 MPa (preferably greater than about 100MPa, and more preferably greater than about 200 MPa), as measuredaccording to ASTM D638-08; a strain at break greater than about 50%(preferably greater than about 90%, more preferably greater than about300%), as measured according to ASTM D638-08; or any combinationthereof.

Preferred ionomers mixtures of an ionic compound and a copolymerincluding a polar monomer and a nonpolar monomer. Non-polar monomersthat may be used in the copolymer of an ionomer include α-olefins, suchas α-olefins having from 2 to about 20 carbon atoms (e.g., from about 2to about 8 carbon atoms). Exemplary nonpolar monomers that may beemployed include ethylene, propylene, 1-butene, 1-hexene, and 1-octene,or any combination thereof. Suitable polar monomers include monomerswhich upon polymerization have an ionic group. Without limitation,examples of polar monomers that may be employed in the copolymer of theionomer include acids, such as acids having from about 2 to about 20carbon atoms (e.g., methacrylic acid, ethacrylic acid. The concentrationof the polar monomer in the copolymer of the ionomer may be less thanabout 40 wt. %, preferably less than about 25 wt. %, and more preferablyless than about 20 wt. %, based on the total weight of the ionomer. Theconcentration of the polar monomer in the Suitable ionic compounds forthe ionomer include compounds containing one or more alkali earthmetals, one or more alkaline earth metals, or both. Without limitation,the ionic compound may include sodium, potassium, lithium, calcium,magnesium, or any combination thereof. Particularly preferred ioniccompounds include sodium hydroxide, potassium hydroxide, calciumhydroxide and magnesium hydroxide. By way of example, commerciallyavailable ionomers include SURLYN® poly(ethylene-co-methacrylic acid)ionomer and NAFION® perfluorosulfonate ionomers.

Preferred polyurethanes include thermoplastics formed from polymerizingone or more diisocyanates and one or more diols. More preferredpolyurethanes include thermoplastic formed from polymerizing one or morediisocyanates and two or more dials. The polyurethane may be athermoplastic polyurethane elastomer, such as one including a firstpolymer block containing a first diol and a second polymer block thanincludes a second diol, where the first block is a relatively hard block(e.g., having a relatively high modulus) and the second block is arelatively soft block (e.g., having a modulus lower than the relativelyhard block). The concentrations of the relatively hard block and therelatively soft block may each independently be greater than about 5 wt.%, preferably greater than about 10 wt. %, and more preferably greaterthan about 20 wt. % based on the total weight of the copolymer. Theconcentrations of the relatively hard block and the relatively softblock may each independently be less than about 95 wt. %, preferablyless than about 90 wt. %, and more preferably less than about 20 wt. %based on the total weight of the copolymer. The total concentration ofthe relatively hard block and the relatively soft block may be greaterthan about 60 wt. %, preferably greater than about 80 wt. %, morepreferably greater than about 95 wt. %, and most preferably greater thanabout 98 wt. % based on the total weight of the polymer. Commerciallyavailable thermoplastic polyurethanes (TPU) that may be employed includeESTANE® brand TPU available from Lubrizol Corporation, ELASTOLAN® brandTPU available form BASF and DESMOPAN® brand TPU available from Bayer.

The thermoplastic polymer may be selected so that it includes relativelylong chains, such that they may have a number average molecular weightgreater than about 20,000, preferably greater than about 60,000, andmost preferably greater than about 140,000. They may be unplasticized,plasticized, elastomer modified, or free of elastomer. Semi-crystallinepolymers may have a degree of crystallinity greater than about 10 wt %,more preferably greater than about 20 wt %, more preferably greater thanabout 35 wt %, more preferably greater than about 45 wt %, and mostpreferably greater than about 55 wt %. Semi-crystalline polymers mayhave a degree of crystallinity less than about 90 wt %, preferably lessthan about 85 wt %, more preferably less than about 80 wt %, and mostpreferably less than about 68 wt %. Crystallinity of the thermoplasticpolymer may be measured using differential scanning calorimetry bymeasuring the heat of fusion and comparing it to art known heat offusion for the specific polymer.

The polymer preferably may be selected so that it has a melt indexsufficiently high so that the polymer can be processed using extrusionequipment. Preferred polymers have a melt flow rate of about 0.05 g/10min or more, about 01 g/10 min or more, or about 0.3 g/10 min or more asmeasured according to ASTM D1238 at 190° C./2.16 kg. The polymerpreferably has a melt index sufficiently low so that the polymer hasgood mechanical properties. Preferred polymers have a melt flow rate ofabout 150 g/10 min or less, about 80 g/10 min or less, about 50 g/10 minor less, about 20 g/10 min or less, or about 4 g/10 min or less asmeasured according to ASTM D1238 at 190° C./2.16 kg.

The polymer preferably may be selected so that it has a sufficientlyhigh dart drop impact (in units of g, measured according to ASTM 1790Aon a 2 mil thick film) so that the polymer resists cracking during ahigh speed stamping operation. Preferred polymers have a dart dropimpact of about 10 g or more, about 40 g or more, about 100 g, or more,about 150 g or more, about 200 g or more, or about 250 g or more, asmeasured according to ASTM D1790A (2 mil).

The polymer of the filled polymeric material may also contain up toabout 10 wt % of a grafted polymer (e.g., a grafted polyolefin such asisotactic polypropylene homopolymer or copolymer) which is grafted witha polar molecule, such as maleic anhydride.

The thermoplastic polymer may include a substantially amorphous polymer(e.g., a polymer having a crystallinity less than about 10 wt. %,preferably less than about 5 wt. %, and most preferably less than about1 wt. %, as measured by differential scanning calorimetry at a rate ofabout 10° C./min). For example, the thermoplastic polymer may include asubstantially amorphous polymer having a glass transition temperaturegreater than 50° C., preferably greater than 120° C., more preferablygreater than about 160° C., even more preferably greater than about 180°C., and most preferably greater than about 205° C., as measured bydynamic mechanical analysis at a rate of about 1 Hz. Exemplary amorphouspolymers include polystyrene containing polymers, polycarbonatecontaining polymers, acrylonitrile containing polymers, and combinationsthereof.

Without limitation, examples of styrene containing copolymers that maybe employed in the filled polymeric material are described inInternational Patent Application Publication WO 2010/021899 (publishedon Feb. 25, 2010 by Mizrahi).

In lieu of or in addition to any thermoplastic polymer, the polymericlayer may employ an elastomer having one or both of the followingproperties: a relatively low tensile modulus at 100% elongation (e.g.,less than about 3 MPa, preferably less than about 2 MPa), a relativelyhigh tensile elongation at break (e.g., greater than about 110%,preferably greater than about 150%) both measured according to ASTMD638-08 at a nominal strain rate of about 0.1 s⁻¹. Examples ofelastomers that may be employed, are described in International PatentApplication Publication WO 2010/021899 (published on Feb. 25, 2010 byMizrahi).

Though it is possible that some amounts of epoxy may be used, thepolymer of the filled polymeric material preferably is substantiallyfree or entirely free of epoxy, or other brittle polymers (e.g.,polymers having an elongation at failure of less than about 20% asmeasured according to ASTM D638-08 at a nominal strain rate of about 0.1s⁻¹), or both. If present, the concentration of epoxy, other brittlepolymers, or both is preferably less than about 20%, more preferablyless than about 10%, more preferably less than about 5%, and mostpreferably less than about 2% by volume, based on the total volume ofthe filled polymeric material.

In one particularly preferred aspect of the teachings, the filledpolymeric material may include one or more polyamide copolymers, one ormore thermoplastic polyurethanes, one or more thermoplasticpolyether-ester copolymers, one or more polyolefins, one or moreionomers, or any combination thereof. The polyamide copolymer may be anyof the polyamide copolymers described above herein. Preferred polyamidecopolymers include polyamide-polyamide copolymers, polyesteramidecopolymers, polyetheresteramides, polycarbonate-esteramide copolymers,or any combination thereof. Any of the thermoplastics may be a randomcopolymer or a block copolymer. Any of the thermoplastics may be athermoplastic elastomer. By way of example, the filled polymericmaterial may include a polyester amide thermoplastic elastomer, apolyetheresteramide thermoplastic elastomer, a polycarbonate-esteramidethermoplastic elastomer, a polyether-ester thermoplastic elastomer, aamide block copolymer thermoplastic elastomer, or any combinationthereof. The filled polymeric material may optionally include one ormore polymers that is not a copolymer. For example filled polymericmaterial may include one or more polyamide homopolymer. Particularlypreferred polyamide homopolymers include polyamide 6 and polyamide 6,6.If employed the concentration of the one or more polyamide homopolymerspreferably is relatively low (e.g., compared with the concentration ofthe one or more copolymers. If present, the concentration of the one ormore polyamide homopolymers preferably is about 50 weight percent orless, more preferably about 40 weight percent or less, even morepreferably about 30 weight percent or less, and most preferably about 25weight percent or less, based on the total weight of the polymer in thefilled polymeric material.

Without limitation, examples of thermoplastic polymers that may beemployed in the filled polymeric material include thermo polyamidecopolymers that may be employed include polyamide copolymers (such asLUMID® available from LG Chemical Ltd., GRIVORY®, GRILAMID®, and GRILON®available from EMS-Grivory (e.g., GRILON® CA 6 E, GRILON® CF6 S, GRILON®CR 8, GRILON® CR 9, GRILLON® BM 13 SBG, or GRILLON BM 20 SBG), AMILAN®available from Toray Resin Company, DURETHAN® available from LanxessCorporation, NYLENE® available from Custom Resins Group, ULTRAMID®available from BASF Corporation, and WELLAMID® available from WellmanEngineering Resins), polyether-amide copolymers (such as PEBAX®available from Arkema), nylon homopolymers (such as AEGIS® availablefrom Honeywell, CHEMLON® available from Teknor Apex Company, NYMAX™available from PolyOne Corporation, and NYPEL® available from BASFCorporation), thermoplastic polyurethanes (such as APILON® availablefrom API SpA, DESMOPAN® available from Bayer Material Science AG, andELASTOLLAN® available from BASF Polyurethanes GmbH). Without limitation,examples of polyolefins that may be employed in the filled polymericmaterial include ethylene copolymers (such as EXACT™ available fromExxonMobil Chemical, DOWLEX® available from Dow Chemical Company, andENGAGE™ available from Dow Chemical Company), polypropylene andpolypropylene copolymers (such as BORMED™ available from Borealis AG,FORMOLENE® available from Formosa Plastics Corporation, USA, VERSIFY™available from Dow Chemical Company, and VISTAMAXX™ available fromExxonMobil Chemical). The thermoplastic polymer may include a moldinggrade, an extrusion grade, a film grade, a blow molding grade, arotation molding grade, or any combination thereof. In one aspect of theinvention, a film grade may provide surprisingly good adhesion with anadjoining sheet material.

In one aspect of the teachings herein, the polymer selected for the corematerial may be generally non-polar while still providing surprisinglygood adhesion with an adjoining sheet material for forming thecomposite.

Nevertheless, the polymers selected for employment herein may begenerally polar. Filled polymeric materials that include a generallypolar polymer may have sufficient attraction between the polar polymerand the metallic fibers so that there is no need for a functionalizedpolymer to improve the adhesion between the thermoplastic and themetallic fibers. As such, the filled polymeric material may besubstantially free of, or even entirely free of polymers having maleicanhydride, acrylic acid, an acrylate, an acetate, or any combinationthereof. For example, the filled polymeric may include or may besubstantially free, or entirely free of maleic grafted polymers. Ifemployed, the concentration of polymers having maleic anhydride, acrylicacid, an acrylate, an acetate, or any combination in the filledpolymeric material preferably about 20 weight percent or less, morepreferably about 10 weight percent or less, even more preferably about 5weight percent or less, even more preferably about 1 weight percent orless, and most preferably about 0.1 weight percent or less, based on thetotal weight of the polymer in the filled polymeric material. By way ofexample, generally polar polymers include acetal homopolymers orcopolymers, polyamide homopolymers or copolymers, polyimide homopolymersor copolymers, polyester homopolymers or copolymers, polycarbonatehomopolymers or copolymers, or any combination thereof. Filled polymericmaterials that include a generally polar polymer may be substantiallyfree of, or entirely free of polyolefin homopolymers and copolymersincluding about 50 weight percent of one or more olefins. If employed,the total concentration of any polyolefin homopolymers and anycopolymers including about 50 weight percent of one or more olefins maybe about 30 weight percent or less, preferably about 20 weight percentor less, more preferably about 10 weigh percent or less, even morepreferably about 5 weight percent or less, and most preferably about 1weight percent or less, based on the total weight of the polymers in thefilled polymeric material.

The filled polymeric material may include a single polymer or a mixtureof two or more polymers as described in paragraph 0056 of U.S.Provisional Patent Application 61/371,360 filed on Aug. 6, 2010,incorporated herein by reference. For example, the filled polymericmaterial may include a mixture of a polyolefin and one or more secondpolymers, such as mixture of a polyolefin and a polar polymer, such asan ionomer. The material may include a sufficient amount of secondpolymer (e.g., the ionomer) so that the polymer adheres to the metallayers, to the metallic fiber, or both. The weight ratio of the secondpolymer to the polyolefin may be about 1:99 or more, about 3:97 or more,about 5:95 or more, about 10:90 or more, or about 20:80 or more. Theweight ratio of the second polymer to the polyolefin may be about 99:1or less, about 90:10 or less, about 70:30 or less, about 50:50 or less,or about 40:60 or less.

Fillers

The filled polymeric material (e.g., the filled thermoplastic polymericlayer) contains one or more fillers. The fillers may be a reinforcingfiller, such as fibers, and more particularly metallic fibers. Metallicfillers (e.g., metallic fibers) that may be employed are described inInternational Patent Application Publication WO 2010/021899 (publishedon Feb. 25, 2010 by Mizrahi), see for example paragraphs 064-081,incorporated herein by reference and paragraphs 52-70, FIGS. 2A, 2B, 2C,2D, 2E, 2F, 2G, 2H, 2I, 2J, 3, and 4 of U.S. patent application Ser. No.12/978,974 (filed on Dec. 27, 2010 by Mizrahi), both incorporated hereinby reference. For example, metallic fibers which may be used in theinvention include fibers formed from metals such as steel (e.g., lowcarbon steel, stainless steel, and the like), aluminum, magnesium,titanium, copper, alloys containing at least 40 wt % copper, otheralloys containing at least 40 wt % iron, other alloys containing atleast 40 wt % aluminum, other alloys containing at least 40 wt %titanium, or any combination thereof. Preferred fibers include, consistessentially of, or consist entirely of steel. If employed, the steel ofthe fibers may be plain carbon steel (e.g., having a carbonconcentration below about 0.2, 0.15 or even 0.08 weight %), though itmay include one or more alloying elements (e.g., Ni, Cr, or otherelements for defining a stainless steel). The fibers may carry asacrificial anode material or element, such as described hereinafter.The fibers may combine a mixture of two or more types of fibers, such asa mixture of fibers of two or more different compositions (e.g., one ofthe fibers may be selected for a sacrificial anode), a mixture of two ormore fibers of different cross-section profiles, of different sizes, orotherwise.

The filled polymeric material may contain other non-metallic conductivefibers, such as those described in Intemational Patent ApplicationPublication WO 2010/021899 (published on Feb. 25, 2010 by Mizrahi).

The filled polymeric material may include a metallic fiber or otherfiller that is capable of reducing or eliminating the corrosion of themetallic layers. In one approach, one or more of the metallic fibers orother fillers in the filled polymeric material may have a relativelyhigh galvanic activity. For example, the metallic fibers or otherfillers in the filled polymeric material may have a higher galvanicactivity than the metal employed for the surface of one or preferablyboth of the metallic layers (of the composite material) in contact withor facing the filled polymeric material. As such, it may be desirablefor the filled polymeric material to be substantially, or even entirelyfree of fillers having a low galvanic activity. By way of example, thisapproach to reducing the corrosion of a composite material may use afilled polymeric material that is substantially or entirely free ofcarbon black. The one or more fillers having a relatively high galvanicactivity preferably have an anodic index that is greater than themetallic layer by about 0.05 V or more, more preferably by about 0.1 Vor more, even more preferably by about 0.20 V or more, and mostpreferably by about 0.25 V or more. The one or more fillers having arelatively high galvanic activity may be any art known material having ahigher galvanic activity than the metallic layer. By way of example,such fillers may includes one or more zinc containing materials, one ormore magnesium containing materials, one or more aluminum containingmaterials, or any combination thereof. The one or more fillers mayinclude a first filler and a second filler having a higher galvanicactivity than the first filler, where the second filler is a sacrificialfiller. If the filled polymeric materials includes a first filler and asacrificial filler, the first filler preferably is a metallic fiber. Thesacrificial filler may have a relatively high total surface area (i.e.,of all of the sacrificial filler particles) compared to the surface areof the metallic layer, the total surface area of the first filler, orpreferably both. For example, the ratio of the total surface are of thesacrificial filler to the surface area of the metallic layer may beabout 1.5 or more, preferably about 3 or more, more preferably about 10or more, and most preferably about 50 or more. If the filled polymericmaterials includes a first filler and a sacrificial filler, the firstfiller may have a surface having a galvanic activity that is less than,equal to, or greater than the galvanic activity of the surface of themetallic layer. If the first filler has a surface having a galvanicactivity greater than the galvanic activity of the surface of themetallic layer, the first filler may function as a sacrificial filler.As such, a second sacrificial filler may not be needed and the filledpolymeric may be substantially or entirely free of a second sacrificialfiller.

The metallic fibers preferably are selected so that the compositematerial has generally good weld characteristics. For example, theconcentration of the metallic fibers, the size of the metallic fibers,the amount of contact between the metallic fibers, the shape of themetallic fibers, the amount of contact between a metallic fiber and themetal layers, or any combination thereof of may be selected so that thecomposite material has a generally good weld processing window, agenerally high electrical conductivity, a generally high static contactresistance, or any combination thereof. A generally good weld processingwindow may be characterized for example by a high weld current range, ahigh weld time range, or both. The weld current range and the staticcontact resistance of the composite material may have features and maybe measured according to the method described in paragraphs 111-117 ofU.S. Provisional Patent Application No. 61/377,599 filed on Aug. 27,2010 and paragraphs 013, 016, 023, 034-039, 076-080 and 121-126 andFIGS. 5-8 of U.S. patent application Ser. No. 12/978,974, filed on Dec.27, 2010, both incorporated herein by reference.

The fibers or any other filler selected for use with the presentteachings is such that, when used in combination with the polymericcomponent herein, and any associated material for defining thecomposite, will provide a weld current range for the composite material,Ic, when welded to a sheet of monolithic steel having the same thicknessas the composite material that is preferably greater than the currentrange for two monolithic sheets of steel, Im, having the same thicknessas the composite material. For example, the materials may be selectedand employed such that the ratio of Ic to Im is preferably about 1.1 ormore, more preferably about 1.2 or more, even more preferably about 1.3or more, even more preferably about 1.4 or more, and most preferablyabout 1.5 or more. The current range of the composite material, Ic, maybe about 1.5 kA or more, about 1.7 kA or more, about 1.9 kA or more,about 2.1 kA, about 2.3 kA or more, or about 2.5 kA or more. The staticcontact resistance of the composite material may be about 0.0020Ω orless, about 0.0017Ω or less, about 0.0015Ω, about 0.0012Ω or less, orabout 0.0008Ω or less. The materials may be selected and employed suchthe ratio of the static contact resistance of the composite material tothe static contact resistance of steel (e.g., cold rolled steel,galvanized steel, galvannealed steel, or any combination thereof) may beabout 1 or more, about 1.2 or more, about 1.5 or more, about 2 or more,about 3 or more, about 4 or more, about 5 or more or about 10 or more.It will be appreciated that if the static contact resistance is toohigh, the composite may have difficulty in passing a current and thusnot be easily welded. As such, the materials may be selected andemployed such that the ratio of the static contact resistance of thecomposite material to the static contact resistance of steel (e.g., coldrolled steel, galvanized steel, galvannealed steel, or any combinationthereof) preferably is about 1000 or less, more preferably about 300 orless, even more preferably about 100 or less, even more preferably about75 or less, and most preferably about 40 or less.

The metallic fibers preferably may have dimensions and distribution ofdimensions as described in International Patent Application PublicationWO 2010/021899 (published on Feb. 25, 2010 by Mizrahi). Withoutlimitation, the metallic fibers may have a weight average length,L_(avg) greater than about 1 mm, more preferably greater than about 2mm, and most preferably greater than about 4 mm. Suitable fibers mayhave an L_(avg) of less than about 200 mm, preferably less than about 55mm, more preferably less than about 30 mm, and most preferably less thanabout 25 mm. The weight average diameter of the fibers may be greaterthan about 0.1 μm, more preferably greater than about 1.0 μm, and mostpreferably greater than about 4 μm. The weight average diameter of thefiber may be less than about 300 μm, preferably less than about 50 μm,even more preferably less than about 40 μm, and most preferably lessthan about 30 μm.

The metallic fibers may have any shape. The metallic fibers may includea curvilinear portion. Generally linear metallic fibers may be used.More preferably the metallic fibers are not straight fibers. By way ofexample, metallic fibers that are not straight, may have one or morebends, may have a generally arcuate profile, may have a generallyhelical shape, or any combination thereof. Metallic fibers that areinitially straight, preferably become fibers that are not straight (suchas described above) when combined with the polymer.

The metallic fibers may have one or more features described inparagraphs 099-102, 157, and FIG. 5 of U.S. Provisional PatentApplication 61/371,360 filed on Aug. 6, 2010, incorporated herein byreference. For example, the cross-section of the metallic fiber (i.e.,in the direction transverse to the length of the fiber) may have one ormore flat sides. As such, a portion of a metallic fiber in the compositemay have a planar contact with a metallic layer, with another fiber, orboth. The metallic fiber may have a cross-section that is generally apolygonal having four or more sides, such as a cross-section that isgenerally rectangular, generally a parallelogram, or generally a square.Such fibers thus may be configured generally as elongated flat ribbonstrips. The ratio of the length (e.g., the average length) to the width(e.g. the weighted average width) of the ribbon strips may be about 2 ormore, about 4 or more, about 8 or more, or about 15 or more. The ratioof the length (e.g., the average length) to the width (e.g. the weightedaverage width) of the ribbon strips may be about 5000 or less, about1000 or less, about 400 or less, about 100 or less, or about 30 or less.The ratio of the width (e.g., the weighted average width) to thethickness (e.g., the weighted average thickness) of the fibers may be 1or more, about 1.4 or more, about 2 or more, about 3 or more, about 5 ormore, or about 7 or more. The ratio of the width to the thickness of thefibers may be about 300 or less, about 100 or less, about 50 or less, orabout 15 or less. Such fibers may be prepared by one or more fiberforming steps, such as a step of cutting a metallic foil (e.g., having athickness that is about the thickness of the fibers) into narrow ribbonstrips (e.g., the spacing between cuts may define the width of thefibers).

The cross-section of the metallic fibers, perpendicular to the length ofthe fiber, may have any geometry. For example, the cross-section may bea polygon (such as a rectangle or square) or other shape havinggenerally straight sides, or the cross-section may include at least oneside that is generally arcuate (for example, the metallic fibers mayhave a cross-section that is entirely arcuate, such as a substantiallycircular, or substantially oval shaped cross-section). Thecross-sectional area of the metallic fibers in the plane transverse tothe longitudinal axis preferably is about 1×10⁻⁶ mm² or more, morepreferably about 1×10⁻⁶ mm² or more, even more preferably about 8×10⁻⁶mm² or more, even more preferably about 1×10⁻⁴ mm² or more, and mostpreferably about 4×10⁻⁴ mm² or more. The cross-sectional area of themetallic fibers in the plane transverse to the longitudinal axispreferably is about 2.5×10⁻² mm² or less, more preferably about 1×10⁻²mm² or less, even more preferably about 2.5×10⁻³ mm² or less, and mostpreferably about 1×10⁻³ mm² or less. For example, it is surprising thatcomposite materials employing steel fibers having a cross-sectional areain the plane transverse to the longitudinal axis that are greater thanabout 8×10⁻⁵ mm² have improved weld process window relative to materialshaving fibers with lower cross-sectional area. Such composite materialsincluding the fibers having a cross-sectional area greater than about8×10⁻⁵ mm² maintain the high drawability and formability observed foundfor the composite materials with thinner fibers.

The metallic fibers may have a substantially constant thickness acrossthe length of the fiber, across the width of the fiber, or both. A flatsurface of the fiber may be smooth (i.e., generally free of texture), ormay have a texture. For example a ribbon-like fiber may have both majorsurfaces that are smooth, both major surfaces that are textured, or onemajor surface that is textured and one major surface that is smooth.

A particularly preferred metallic fiber that may be used, optionallywith one or more other fibers, is a steel fiber (e.g., a carbon steelfiber) having a generally rectangular cross-section (e.g., for defininga profile for the generally flat ribbon strips) in the directiontransverse to the length. The metallic fiber may have a weighted averagethickness of about 10 to about 70 μm, a weighted average width of about40 to about 200 μm, a weighted average length of about 0.8 to about 5mm, or any combination thereof.

When used in the polymeric layer between two metallic layers, themetallic fibers preferably are present as a mass of fibers. The mass ofmetallic fibers preferably includes a large number of fibers (e.g., 20or more, 100 or more, 1000 or more, or 10000 or more). The mass ofmetallic fibers may be interconnected. The mass of metallic fibers maybe entangled. The mass of fibers may form mechanical interlocks (i.e.,two or more fibers may be mechanically interlocked). The mass ofmetallic fibers preferably spans with thickness of polymeric layer sothat the mass of fibers (e.g., the network of metallic fibers)electrically connects the two metallic layers. Although a singlemetallic fiber may span the thickness of the polymeric layer, preferablynone of the metallic fibers span the thickness of the polymeric layer.If metallic fibers span the thickness of the polymeric layer, thefraction of the fibers that span the thickness preferably is about 0.4or less, more preferably about 0.20 or less, even more preferably about0.10 or less, even more preferably about 0.04 or less, and mostpreferably about 0.01 or less. The fibers in the mass of fiberspreferably are arranged in a non-ordered arrangement. For example, themaximum number of neighboring metallic fibers that are arranged in agenerally aligned arrangement may be less than about 100, preferablyless than about 50, more preferably less than about 20, even morepreferably less than about 10, and most preferably less than about 5.More preferably the mass of fibers are arranged in a generally randomarrangement. Individual metallic fibers that contact a surface of one ofthe metallic layers preferably are free of a planar contact (e.g., overthe length of the fiber). As such, the composite material may becharacterized as being essentially free, or even entirely free of planarcontacts between a metallic fiber and a metallic layer. Fibers thatcontact a metallic surface, preferably have a line contact, a pointcontact, or a combination, thereof. Some of the metallic fibers maycontact one of the metallic layers, however few, if any of the metallicfiber will contact a metallic layer over a large portion of the lengthof the metallic fiber. As such, a large fraction of the metallic fibersdo not contact a metallic layer or at least have a significant portionthat is not in contact with the metallic layer. The fraction of themetallic fibers that contact a metallic layer along at least half of thelength of the fiber is preferably about 0.3 or less, more preferablyabout 0.2 or less, even more preferably about 0.1 or less, even morepreferably about 0.04 or less, and most preferably about 0.01 or less.

The metallic fibers are preferably sufficiently thin and present in asufficient concentration so that many fibers are arranged between thesurfaces of the layer. For example, the average number of fibers thatintersect a line parallel to the thickness direction of the polymericlayer and going through the polymeric layer preferably is about 3 ormore, more preferably about 5 or more, more preferably about 10 or more,and most preferably about 20 or more. Without being bound by theory, itis believed that a large number of metallic fibers advantageously allowsfor more homogeneous deformation of the material, such as during astamping process.

The concentration of the metallic fibers is preferably greater thanabout 1 volume %, more preferably greater than about 3 volume %, evenmore preferably greater than about 5 volume %, even more preferablygreater than about 7 volume %, even more preferably greater than about10 volume %, and most preferably greater than about 12 volume % based onthe total volume of the filled polymeric material. The metallic fibersmay be present in the filled polymeric material at a concentration lessthan about 60 volume %, preferably less than about 50 volume %, morepreferably less than about 35 volume %, still more preferably less thanabout 33 volume %, and most preferably less than about 30 volume %(e.g., less than about 25 volume %, or even less than about 20, 10, or 5volume %). For example the amount of fiber may be about 1%, 2%, 3%, 4%,5%, 6%, 7%, 8%, 9%, or 10%, by volume based on the total volume of thefilled polymeric material, or within a range bounded by those values(such as from about 1% to about 6%). It is possible that compositesherein may employ a concentration of metallic fibers that surprisinglyis substantially lower than the amount of a particle filler necessary toachieve similar welding characteristics. Moreover, it is also possiblethat the fibers and materials are selected so that better weldingperformance surprisingly may be realized at a relatively lowconcentration of metallic fibers as compared with an identical compositematerial having a higher concentration of metallic fibers. For example,it is surprisingly seen that using a filled polymeric material havingabout 10 volume % metallic fiber results in composite materials havingsuperior welding characteristics compared with those made with filledpolymeric materials having higher concentrations of metallic fiber.

The thermoplastic polymer material may be present in the filledpolymeric material at a concentration greater than about 40 volume %,preferably greater than about 65 volume %, more preferably greater thanabout 67 volume %, still more preferably greater than about 70 volume %,and most preferably greater than about 75 volume % (e.g., at least about80 volume %, at least about 90 volume %, or even at least about 95volume %).

The volume ratio of the polymer (e.g., the thermoplastic polymer) to thefibers (e.g., the metallic fibers) is preferably greater than about2.2:1, more preferably greater than about 2.5:1, and most preferablygreater than about 3:1. The volume ratio of the polymer (e.g., thethermoplastic polymer) to the fibers (e.g., the metallic fibers) ispreferably less than about 99:1, more preferably less than about 33:1,even more preferably less than about 19:1, and most preferably less thanabout 9:1, (e.g., less than about 7:1).

The material of any core in the sandwich composites herein may containpores or voids, or may be substantially free of pores and voids.Preferably, the concentration of pores and voids in the filled polymericmaterial is less than about 25 volume %, more preferably less than about10 volume %, still more preferably less than about 5 volume %, and mostpreferably less than about 2 volume % (e.g., less than about 1% byvolume), based on the total volume of the filled polymeric material.

The fiber (e.g., the conductive fiber, such as the metallic fiber)preferably is present at a concentration greater than about 40 volume %,more preferably greater than about 70 volume %, and most preferablygreater than about 80% (e.g., greater than about 90 volume %, or evengreater than about 95 volume %) based on the total volume of the fillerin the filled polymeric material.

The combined volume of the polymer (e.g., thermoplastic polymer) and themetallic fibers is preferably at least about 90% by volume, morepreferably at least about 95% by volume and most preferably at leastabout 98% by volume based on the total volume of the filled polymericmaterial.

The metallic fibers provide one or any combination of electricconductivity for welding, a reinforcement for strengthening, or strainhardening the polymeric structure by utilizing fibers that as metals arecapable of extending and imparting better strain hardening properties tothe polymeric core. As such, the tensile elongation (at failure) of themetal fibers is preferably greater than about 5%, more preferablygreater than about 30%, and most preferably greater than about 60% asmeasured according to ASTM A370-03a.

It is possible that the materials herein may employ in combination withfibers, a metallic particle. Metallic particles may be spherical,elongated, or of any shape other than a fiber shape. Metallic particleswhich may be employed include those described in International PatentApplication Publication WO 2010/021899 (published on Feb. 25, 2010 byMizrahi).

The fibers (e.g., the metallic fibers) or the combination of the fibersand the metallic particles preferably are dispersed (e.g., randomlydispersed) in the polymeric matrix at a volumetric concentration of lessthan about 30% (more preferably less than about 25%, and most preferablyless than about 20%) by volume of the total polymeric layer). Ifmetallic particles are employed, the ratio of the volume of the fibers(e.g., the metallic fibers) to the volume of the metallic particles inthe filled polymeric material layer may be greater than about 1:30,preferably greater than about 1:1, and most preferably greater thanabout 2:1.

In one aspect of the invention, metallic particles, metallic fibers, orboth may be obtained by a step of grinding offal and/or scrap such asdescribed in International Patent Application Publication WO 2010/021899(published on Feb. 25, 2010 by Mizrahi), see for example paragraph 124,incorporated herein by reference.

Metal Layers

As discussed, it is envisioned that composites herein may employ asandwich structure by which a mass of a polymeric core is flanked onopposing sides by spaced apart layers. For example, a structure hereinmay include two sheets (e.g., metal sheets) that have a metal fiberreinforced polymeric core material disposed between the sheets andpreferably in contact with the sheets. The metal layers (e.g., the firstmetallic layer and the second metal layer) of the sandwich constructionmay be made of a suitable material (e.g., metal) in the form of foils orsheets or other layers having equal or unequal thickness (e.g., averagethickness) across the layer. Each metallic layer may have a generallyconstant thickness or may have a thickness that varies. The face metalon each side may be made of materials having the same or differentproperties and be made of the same or different metals. If the metalfaces are made of metal sheets of unequal thickness, materials havingdifferent properties, or materials having different metal. The compositematerial may have a marking or other means of identifying anddistinguishing the different metal faces. The layers may be the same ordifferent in composition, size (e.g., thickness, width, volume, orotherwise), shape, or other features, relative to each other layer.

Examples of metal layers that may be employed are described in describedin International Patent Application Publication WO 2010/021899(published on Feb. 25, 2010 by Mizrahi), see for example paragraphs082-091, incorporated herein by reference. Preferred metal layersinclude, or consist essentially of, or consist entirely of one or moresteels.

Particularly preferred steel metal layers may be prepared using aprocess including one or more hot rolling steps, one or more coldrolling steps, one or more annealing steps, one or more cleaning steps,one or more tempering steps (e.g., a single roll, a double roll, orotherwise) or any combination thereof. Particularly preferred steelmetal layers may have one or both surfaces that is bright (e.g., havinga smooth finish or a lustrous smooth finish), stone (e.g., having agrindstone pattern), matte (e.g., having a satin finish or a blastedfinish), or any combination thereof. The steel may be bare steel orotherwise coated, plated or treated, such as known in the art ordescribed herein. Without limitation, a steel metal layer may include orconsist essentially of, or consist entirely of tin milled black plate.

The metal layers may have one or more surfaces plated or coated (e.g.,with a thin film), or having one or more other surface treatment (e.g.,a treatment that cleans, etches, roughens, or chemically modifies asurface). A metal face may have one or more coatings, platings orsurface treatments that improves the adhesion of a filled polymericmaterial to the metal layer. The metal layers may have one or moresurfaces plated, coated or otherwise treated that provides corrosionresistance, improves adhesion to a paint or primer, improves stiffness,or any combination thereof. Exemplary coatings and platings may includeone or any combination of galvanized, electrogalvanized, chrome plating,nickel plating, corrosion resistance treatment, e-coat, zinc coated,Granocoat, Bonazinc and the like. It will be appreciated that one ormore coatings, platings, or surface treatments may be performed on thecomposite material, (e.g., after the composite material is prepared). Assuch, a surface of the metal layer facing the filled polymeric layer maybe free of a coating, plating or surface treatment and an exposedsurface of the metal layer may have a coating, plating or surfacetreatment. One or both metal faces may be free of a coating, plating orsurface treatment (for example, the filled polymeric material may betreated or selected so that it provides good adhesion to the metal layerwithout the need for a coating, plating, or surface treatment).

One or both of the metal faces preferably may be relatively thick, suchthat the metal face does not wrinkle, tear, or form other defects whenpreparing and/or processing the composite material. Preferably, thethickness of one or both of the metal faces is at least about 0.05 mm,more preferably at least about 0.10 mm, even more preferably at leastabout 0.15 mm, and most preferably at least about 0.18 mm. The sheetsmay have a thickness less than about 3 mm, preferably less than about1.5 mm, and more preferably less than about 1 mm, and most preferablyless than about 0.5 mm. For example, the composite material may be usedin an automotive panel requiring at least one class A or class Bsurface, preferably at least one class A surface (e.g., after a stampingstep, a welding step, an electrocoating step, a painting step, or anycombination thereof). Such a composite material may have a first surfacewhich is a class A surface and a second surface which is not a class Asurface. The class A surface may be the surface of a first metal facehaving a relatively high thickness and the surface that optionally isnot a class A surface may be the surface of a second metal face having arelatively low thickness (e.g., at least about 20% or even at leastabout 40% less than the thickness of the first metal face). In general,the ratio of the thickness (e.g., average thickness) of the first metallayer to the thickness of the second metal layer may be from about 0.2to about 5, preferably from about 0.5 to about 2.0, more preferably fromabout 0.75 to about 1.33 and most preferably from about 0.91 to about1.1.

Surprisingly, the filled polymeric layer may provides sufficientstiffness with respect to the flexural modulus of the composite materialso that down gauging is possible, for example by employing a highstrength steel for one or more metallic layers of the light weightcomposite material, such as described in paragraphs 120 and 121 of U.S.Provisional Patent Application No. 61/377,599 filed on Aug. 27, 2010,incorporated herein by reference. The first metal layer, the secondmetal layer, or both may include a sufficient amount of high strengthsteel so that the flexural modulus of the composite material is at leastabout 200 GPa, as measured according to ASTM D790, wherein theconcentration of the filled polymeric layer is at sufficiently high sothat the density of the composite material is about 0.8 d_(m) or less,where d_(m) is the weighted average density of the first metal layer andthe second metal layer. Surprisingly such composite materials may haveone or both of the following characteristics a high yield strength ofabout 100 MPa or more, about 120 MPa or more, about 140 MPa or more,about 170 MPa or more, about 200 MPa or more, or about 240 MPa or more);or a high tensile strength of about 160 MPa or more, about 200 MPa ormore, about 220 MPa or more, about 250 MPa or more, about 270 MPa ormore, about 290 MPa or more, or about 310 MPa or more.

Composite Material

The composite material may be in the form of a multi-layered sheet,e.g., a sandwich structure including sheets of a material such as ametal that sandwich a core of the filled polymeric material. The sheetsmay have a total average thickness less than about 30 mm, preferablyless than about 10 mm, more preferably less than about 4 mm and mostpreferably less than about 2 mm; and preferably greater than about 0.1mm, more preferably greater than about 0.3 mm, and most preferablygreater than about 0.7 mm). The composite material may have a generallyuniform thickness or the composite material may have a thickness thatvaries (e.g., a random or periodic variation in one or more directions).For example, the variation in the thickness may be such that thestandard deviation of the thickness is less than about 10% of theaverage thickness. The standard deviation of the thickness is preferablyless than about 5% of the average thickness, more preferably less thanabout 2% of the average thickness, and most preferably less than about1% of the average thickness.

The thickness of the filled polymeric layer may be greater than about10%, 20% 30%, 40%, or more of the total thickness of the compositematerial. The volume of the filled polymeric layer may be greater thanabout 10%, 20%, 30%, 40%, or more of the total volume of the compositematerial. Preferably, greater than 50% of the volume of the compositematerial will be the filled polymeric material. The concentration of thefilled polymeric material is more preferably greater than about 60volume % and more preferably greater than about 70 volume % based on thetotal volume of the composite material. The concentration of the filledpolymeric material is typically less than 92 volume % based on the totalvolume of the composite material; however, higher concentrations may beused, particularly in relatively thick composites (e.g., having athickness greater than about 1.5 mm).

The total thickness of outer layers of a sandwich composite structureherein (e.g., metallic layers) may be less than about 70% of the totalthickness of the composite material. The total thickness of metalliclayers preferably is less than about 50%, more preferably less thanabout 40% and most preferably less than about 30% of the total thicknessof the composite material. The total thickness of the outer layers(e.g., the metallic layers) may be greater than about 5%, preferablygreater than about 10%, and more preferably greater than about 20% ofthe total thickness of thickness of the composite material.

The polymeric core layer preferably is in direct contact or indirectcontact (such as via a primer and/or adhesive layer) with at least aportion of the surface of the adjoining layers (e.g., one or moremetallic layer) facing the core layer. Preferably, the area of contactis at least about 30%, more preferably at least about 50%, mostpreferably at least about 70% of the total area of the surface of theadjoining layer facing the polymeric core layer. If a primer or adhesivelayer is employed, the thickness preferably is sufficiently low so thatit does not affect the electrical characteristics of the compositematerial. If employed, the ratio of the thickness of the primer and/oradhesive layer to the thickness of the polymeric core layer preferablyis about 0.30 or less, more preferably about 0.20 or less, even morepreferably about 0.10 or less, even more preferably about 0.05 or less,and most preferably about 0.02 or less. Two adjacent metallic layerspreferably are substantially not in contact with each other. If asurface of a first metallic layer contacts a second metallic layer, theratio of the area of contact to the area of the surface of the firstmetallic layer is preferably about 0.3 or less, more preferably about0.1 or less, even more preferably about 0.05 or less, even morepreferably about 0.02 or less, and most preferably about 0.01 or less.

The composite material may include a plurality of polymeric core layers.For example, the composite material may include one or more core layerswhich includes an adhesive such that it adheres to a metallic layer, adifferent core layer, or both.

The composite material may have a relatively high stiffness to densityratio, such as described in described in International PatentApplication Publication WO 2010/021899 (published on Feb. 25, 2010 byMizrahi), see for example paragraphs 042, 090, 118, and 143-143,incorporated herein by reference.

Surprisingly, the filled polymeric material, the core layer, or thecomposite materials, according to the teachings herein may have goodsound insulation characteristics, high sound dampening, low soundtransmission, reduce sound generation, reduce vibrations, or anycombination thereof. For example, despite, having a sufficientconcentration of metallic fibers so that the composite material may bewelded using resistance welding, the composite material may provide lowacoustical transmission characteristics. The composite material may haveacoustical transmission properties such as described in IntemationalPatent Application Publication WO 2010/021899 (published on Feb. 25,2010 by Mizrahi, paragraph 111, incorporated herein by reference. Thecomposite material according to the teachings herein, may include a corelayer that reduces acoustical transmission, reduces sound generation,reduces vibrations, or any combination thereof. The peak acousticaltransmission (e.g., as measured according to SAE J1400), the peakvibration transmission, or both, through the composite materialpreferably may be less than the value for a monolithic material havingthe same dimensions, more preferably by at least 10%, even morepreferably by at least 50%, and most preferably by at least 90%

Process for Preparing the Filled Polymeric Layer and the Composite

The process for preparing the filled polymeric material and thecomposite material may employ a process described in Intemational PatentApplication Publication WO 2010/021899 (published on Feb. 25, 2010 byMizrahi), see for example paragraphs 092-107, incorporated herein byreference.

The composite material may be prepared using a process that results inthe filled polymeric material (e.g., core layer) being bonded to atleast one adjoining layer (e.g., a metallic sheet) and preferably beinginterposed between two layers (e.g., two metallic layers) and bonded toone or both layers. The process may include one or any combination ofsteps of heating, cooling, deforming (e.g., forming, such as bystamping), or bonding, in order to arrive at a final desired article. Itis envisioned that at least one, or even all of the adjoining layers(e.g., metallic layers) may be provided in the form of a rolled sheet, aforging, a casting, a formed structure, an extruded layer, a sinteredlayer, or any combination thereof.

The sheets may be heated to a temperature greater than about 90° C.(e.g. greater than about 130° C., or greater than about 180° C.).Preferably, the sheets are heated to a temperature greater than aboutT_(min), where T_(min) is the highest glass transition temperature(T_(g)) and melting temperature (T_(m)) of the thermoplastic of thefilled polymeric material. The metallic sheets, the filled polymericmaterial, or both may be heated to a maximum temperature above which thepolymer (e.g., the thermoplastic polymer) may undergo significantdegradation. The thermoplastic polymer may be heated to a temperaturepreferably less than about 350° C., more preferably less than about 300°C. The heated polymer may be mixed with the metallic fiber, and with anyadditional filters. The heated polymer (e.g., thermoplastic polymer) maybe extruded as a sheet layer. The sheet layer may be extruded directlybetween the metal faces, or placed between the metal faces later in theprocess or in a separate step. The process may include one or more stepsof drying the polymer so that the concentration of water in the polymeris below a predetermined maximum moisture concentration. A step ofdrying the polymer may occur before, during, or after a step of heatingthe polymer. The process may include one or more steps of storing apolymer, a polymeric core layer, or a composite material in low humidityenvironment so that the concentration of water in the polymer ismaintained below a predetermined maximum moisture concentration.

The polymeric core layer may be a homogeneous layer or may comprise aplurality of sublayers. For example, the filled polymeric material maycontain an adhesive layer such as described in International PatentApplication Publication WO 2010/021899 (published on Feb. 25, 2010 byMizrahi).

The process for fabricating the composite material may also include oneor more steps of heating one or more metal layers, applying pressure tothe layers, calendaring a polymer (e.g., a thermoplastic polymer or thethermoplastic polymer compounded with the metallic fiber and theoptional fillers), and annealing the composite sheet (e.g., at atemperature greater than the melting temperature of any thermoplasticpolymer in the material).

The process for preparing the filled polymeric material (e.g., a corelayer for the sandwich composites herein) may include a step ofcontacting the fiber and at least a portion of the polymer (e.g.,thermoplastic polymer), blending the fiber and at least a portion of thepolymer, or both. The process of forming the polymeric layer may be acontinuous process or a batch process. Preferably, the process is acontinuous process. The blending or contacting step may include heatingthe polymer to a maximum temperature greater than about 90° C., greaterthan about 140° C., greater than about 170° C., or greater than about190° C. The blending or contacting step may include heating the polymerto a maximum temperature less than about 350° C. less than about 300°C., less than about 280° C., less than about 270° C. or less than about250° C.

The process may employ one or more steps of applying pressure when atleast some of the polymer of the filled polymeric material is at atemperature greater than about 80° C., preferably greater than about120° C., more preferably greater than about 180° C., even morepreferably greater than about 210° C., and most preferably greater thanabout 230° C. The step of applying pressure may employ a maximumpressure greater than about 0.01 MPa, preferably greater than about 0.1MPa, more preferably greater than about 0.5 MPa, even more preferablygreater than about 1 MPa, and most preferably greater than about 2 MPa.The maximum pressure during the step of applying pressure may be lessthan about 200 MPa, preferably less than about 100 MPa, more preferablyless than about 40 MPa, and most preferably less than about 25 MPa. Theprocess may also include a step of cooling the composite material (e.g.to a temperature below T_(min), preferably below the melting temperatureof polymer of the filled polymeric material, and more preferably belowabout 50° C.).

The composite material may be or include a laminate, such as describedin International Patent Application Publication WO 2010/021899(published on Feb. 25, 2010 by Mizrahi).

It may desirable to prevent water (liquid, gas, or solid) fromcontacting the polymeric material so that the moisture level in thepolymeric material is low, so that the filler in the polymeric materialdoes not corrode, or both. As such, the process for preparing thecomposite material may include one or more steps of substantiallyprotecting an edge of the composite material from contact with a liquidor gas. For example, a coating or protective layer may be placed overone or more (or preferably all) of the edges of a polymeric layer (corelayer), one or more (or preferably all) of the edges of the compositematerial may be sealed, or any combination thereof. If employed, acoating or protective layer placed over an edge of a polymeric layerpreferably includes one or more materials that have a relatively lowpermeability to moisture compared to the polymer of the filled polymericmaterial. Any material having relatively low permeability to moisturemay be used. Without limitation, a low permeability material may includea layer of polyethylene vinyl alcohol or a copolymer thereof, a layer ofa polyolefin homopolymer, or a copolymer consisting substantially of oneor more olefins, or any combination thereof. A coating or protectivelayer may be permanently attached to the polymeric layer, to themetallic layer or both. Alternatively, a coating or protective layer maybe used temporarily. For example, a coating or protective layer may beremoved prior to one or more forming steps, prior to one or more weldingsteps, prior to one or more electrocoating steps, or prior to one ormore painting steps. Any edges of the composite material may be sealedusing any art known mean that forms one or more sealed spaces betweenthe metallic layers. By way of example, the metallic layers may bewelded together near an edge. The metallic layers may be welded togetheralong the entire periphery of the composite material.

One or more steps of monitoring the quality of the parts may be employedduring or after assembly of components of the polymeric layer or thecomposite material. The monitoring may be for the purpose of assuringbond integrity between two or more layers, assuring proper dispersion offibers, detecting surface abnormalities (such as cracks, blemishes,creases, roughness, and the like), detecting voids, determining thethickness distribution (e.g., average thickness, mean thickness,thickness variation, minimum thickness, maximum thickness, or anycombination thereof) of one or any combination of layers of thecomposite, or any combination thereof.

One approach may include a step of monitoring the part (e.g., thepolymeric material or the composite material) with one or more probes.The monitoring may be done optically (such as to detect surface defects,to determine a thickness or thickness distribution, a temperature suchas by infrared measurement, or any combination thereof). It may be doneby measuring a response of the part to one or more external stimulus.For example, electrical conductivity, electrical resistivity, impedance,or some other electrical characteristic may be measured in response toor more applied electrical stimulus. For example a probe may be used tomeasure the electrical characteristic at one or more location on thepart (consecutively and/or essentially simultaneously in response to theelectrical stimulus. A magnetic characteristic may be monitored insimilar manner. The stimulus may be a magnetic field and the responsemay be a mechanical response, an electrical response, a magneticresponse, or any combination thereof. The monitoring may be doneacoustically (e.g., using a probe or other source of sound waves such asultrasound waves). Acoustical measurements may be employed for detectingvoids, cracks, compositional distributions, and the like.

A preferred assembly for monitoring may include a source of electricityone or more probes (e.g. a plurality of probes on a common carrier(possible even an array of probes) that essentially spans the part forassessing quality or that is translated over the part to obtainmeasurements), and at least one processor for receiving signals from theprobes. The processor may perform an operation such as comparing thesignals with a predicted value range for the measured part, andsignaling when the measured value is outside of a predicted range, orotherwise falls within a certain predetermined range. FIG. 2 illustratesan example of such a system.

A layered workpiece 12 of the present teachings (e.g. a laminate ofmetallic layers 14, 14′ sandwiching a polymeric layer 16 containingmetallic fibers) is assembled. After the layers are joined a stimulus isapplied (e.g., an electrical stimulus applied by an electrical source102) to one or more of the metal layers 14, 14′, the polymeric layer 16,or any combination thereof. The electrical stimulus may be transmittedto the one or more metal layers using one or more wires 110 or othermeans of electrical communication.

One or more probes 104 may be carried by a carrier 106, and will measurea response of the workpiece to the stimulus. The probes may be on one orboth sides of the workpiece. The measured response may be signallytransmitted to a processor 108, which may also be in controlling orother signaling communication with the stimulation source. (e.g.electrical source 102).

It will be appreciated that the monitoring process described herein mayalso be used for monitoring a polymeric material (e.g., a pellet, asheet, or other sample of the polymeric material).

Forming Process

The composite material of the present invention may be subjected to asuitable forming process, such as a process that plastically deforms amaterial and may include a step of stamping, roll forming, bending,forging, punching, stretching, coiling, some other metalworking, or anycombination thereof. A preferred forming process is a process thatincludes a step of stamping the composite material. The stamping processmay occur at or near ambient temperatures. For example, the temperatureof the composite material during stamping may be less than about 65° C.,preferably less than about 45° C., and more preferably less than about38° C. The forming process may involve drawing regions of the compositematerial to various draw ratios. In one aspect of the invention, thecomposite material is subjected to a step of drawing to a relativelyhigh draw ratio without breaking, wrinkling, or buckling. For example,it is subjected to a step of drawing so that at least a portion of thecomposite is drawn to a draw ratio greater than 1.2. Desirably, thecomposite material may be capable of being drawn and is drawn to amaximum draw ratio greater than about 1.5, preferably greater than about1.7, more preferably greater than about 2.1, and most preferably greaterthan about 2.5. The cracking limit of the draw ratio may be determinedusing the circular cup drawing test as described by Weiss et al. (M.Weiss, M. E. Dingle, B. F. Rolfe, and P. D. Hodgson, “The Influence ofTemperature on the Forming Behavior of Metal/Polymer Laminates in SheetMetal Forming”, Journal of Engineering Materials and Technology, October2007, Volume 129, Issue 4, pp. 534-535), incorporated herein byreference. The forming process may include a step applying a pressure toa die (e.g., a die having a hardness, as measured according to Mohrshardness scale, greater than the hardness of the metallic fibers) incontact with the composite material.

Suitable forming processes that may be employed include those describedin International Patent Application Publication WO 2010/021899(published on Feb. 25, 2010 by Mizrahi), see for example paragraphs105-107, incorporated herein by reference.

After forming a composite material, the process may include one or moresteps of protecting an edge of the composite material to reduce thepenetration of moisture into the filled polymeric material. Any of theaforementioned steps for protecting an edge of the composite materialmay be used.

Characteristics of Composites

The polymeric layer, the composite material, or both, may have a lowspringback angle, a relatively low electrical resistivity, goodweldability (e.g., using resistance welding), relatively low thermalconductivity, relatively low sound transmission, or any combinationthereof, such as described in International Patent ApplicationPublication WO 2010/021899 (published on Feb. 25, 2010 by Mizrahi).

Preferably, the filled thermoplastic material, the composite material,or both is weldable (e.g., weldable using a resistance welding techniquesuch as spot welding, seam welding, flash welding, projection welding,or upset welding) and has a relatively low electrical resistance. Theteachings herein thus also contemplate one or more steps of welding thecomposite materials taught herein. The electrical resistance of thecomposite material in the through-direction may be described by the sumof the electrical resistance of the metallic layers and the core layer.Typically, the electrical resistance of the metallic layers is much lessthan the electrical resistance of the core layer, such that theelectrical resistance of the composite material may be estimated by theelectrical resistance of the core layer. The resistivity (e.g., theresistivity measured in the through-thickness direction, normal to theplane of a sheet) may be measured using AC modulation and determinedfrom the voltage drop, V, and the current, I:Resistivity=(V/I)(A/t)where A is the area of the sheet, and t is the thickness of the sheet.The resistivity (in the through-thickness direction) of the compositematerial, the core layer, or both, may be relatively low (e.g., thecomposite material, the core layer (e.g., the filled thermoplasticmaterial), or both, may be characterized by a resistivity less thanabout 100,000 Ω·cm, preferably less than about 10,000 Ω·cm, morepreferably less than about 3,000 Ω·cm, and most preferably less thanabout 1,000 Ω·cm).

The composite materials may be welded using any welding process known toone of ordinary skilled in the art of welding metals. The weldingprocess may include one or more of the steps, devices, or processesdescribed in International Patent Application Publication WO 2010/021899(published on Feb. 25, 2010 by Mizrahi), U.S. Patent Application61/290,384 (filed on Dec. 28, 2009 by Mizrahi), and paragraphs 22-122 ofU.S. patent application Ser. No. 12/978,974 (filed on Dec. 27, 2010 byMizrahi), all incorporated herein by reference.

Preferred composite materials have a relatively good corrosionresistance. The composite material preferably is characterized by a rateof corrosion of a surface of a metallic layer facing a core layer, thecore layer including a polymer and a metallic filler, that is lower than(more preferably at least 50% lower than) the rate of corrosion of asurface of a metallic layer facing a core layer of an identicalcomposite material except the metallic filler in the core layer isreplaced with the polymer of the core layer. For example, the compositematerial may have a rate of corrosion of a surface of a metallic layerfacing a core layer, the core layer including a sacrificial filler, thatis lower than the rate of corrosion of a surface of a metallic layerfacing a core layer of an identical composite material except thesacrificial filler is replaced with the polymer of the core layer. Therate of corrosion in water may be determined by placing samples of acomposite material having predetermined dimensions, in a water bath at apredetermined corrosion test temperature for a predetermined corrosiontest time, and measuring the amount of corrosion on a surface. The rateof corrosion in salt water may be determined by placing samples of acomposite material having predetermined dimensions, in a salt water bathhaving a predetermined salt concentration, at a predetermined corrosiontest temperature for a predetermined corrosion test time, and measuringthe amount of corrosion on a surface. Without limitation the, corrosiontest temperature may be about 40° C., and the corrosion test time may beabout 168 hours.

Microstructure of Weld

It is possible that weld joints made using various composites taughtherein may exhibit a variation of microstructures across the compositesuch as described in International Patent Application Publication WO2010/021899 (published on Feb. 25, 2010 by Mizrahi), see for exampleparagraphs 112-117, incorporated herein by reference.

The composite materials of the present invention may be used in anynumber of applications requiring one or any combination of theproperties described herein, including but not limited to relatively lowdensity, relatively low thermal conductivity, relatively high stiffnessto density ratio, or relatively low acoustical transmission. Exemplaryapplications which may employ the composite materials of the presentinvention may include automotive and other transportation relatedapplications, building construction related applications, and appliancerelated applications. The composite materials may be used inapplications such as an automotive panel, a truck panel, a bus panel, acontainer (e.g., a container used for shipping), a panel on a train car,a panel on a jet, a tube (e.g., a bicycle tube), a motorcycle panel(e.g., a cowling or fairing), a trailer panel, a door inner (e.g., avehicle door inner), a roof panel, a vehicle hood inner, a vehicle floorpan, a vehicle rear shelf panel, a vehicle rear compartment panel, avehicle back seat pane, a vehicle decklid inner, a panel on arecreational vehicle, a panel on a snowmobile, an automotive bumperfascia, a spoiler, a wheel well liner, an aerodynamic ground effect, anair dam, a container, a bed liner, a divider wall, an appliance housing,a vehicle fuel filler door, a vehicle bumper, a decorative insert, aduct, a grab bar, a storage compartment door, a housing for anelectronic device (such as a cellular phone, a computer, a camera, atablet computer, a music or video storage device, or a music or videoplayer), a console, an air inlet part, a battery housing, a grille, awheel well, or a seat pan. The composite materials may be used as abuilding construction material, such as an exterior trim element,flashing, gutters, shingles, walls, flooring, countertops, cabinetfacing, window frames, door frames, paneling, vents, ducts, planking,framing studies, shelving, plumbing fixtures, sinks, shower pans, tubs,and enclosures. An exemplary application is an vehicle body panel (e.g.,a body outer skin of a vehicle such as an automobile). Automobile panelswhich may use the composite materials described herein include frontquarter panels, rear quarter panels, door panels, hood panels, roofpanels, or otherwise. The automotive panel may have a class A, class B,or class C surface, preferably a class A or class B surface, and morepreferably a class A surface. The composite materials herein may alsoinclude one or more decorative outer surfaces or veneers, such as ametal veneer, a wood veneer, a polymeric veneer, or otherwise. The outersurface may have a different texture, color or other appearance as anopposing layer. For example, a ferrous outer layer may be colored sothat it simulates a copper color, a bronze color, a brass color, a goldcolor, or some other color.

The composite materials of the present invention may be used in aprocess that includes a step of coating the composite material, such asan electrocoating process, a paint process, a powder coat process, anycombination thereof, or the like. If employed, the coating process mayinclude one or more steps of cleaning or otherwise preparing thesurface, one or more steps of heating or baking the coating (e.g., at atemperature greater than about 100° C., preferably greater than about120° C.), or any combination thereof. The coating may be applied by anyconventional means, such as by a dipping process, a spraying process, orwith a process employing an applicator such as a roller or a brush. Assuch, the composite material preferably is free of ingredients (e.g.,low molecular weight ingredients) that leach out and contaminate a bathof a coating process, such as a bath of an electrocoat process.Likewise, methods herein include one or more coating steps that are freeof bath contamination due to an ingredient of the composite.

The composite material (e.g., a stamped part formed of the compositematerial) may be used in an assembly which requires joining thecomposite material to one or more other materials or parts. For examplethe composite material may be mechanically joined to another part usinga fastener, or chemically joined to another part using an adhesive, anadhesion promoter (e.g., a primer), or both. Other means of joininginclude welding, brazing, and soldering. One or any combination of thesejoining methods may be employed.

Preferably, the composite material does not delaminate (e.g., themetallic layer does not delaminate from the core layer) during theprocessing of the composite material to form a part or an assembly, orduring the use of the part. As such, the composite material preferablydoes not delaminate during a stamping operation, during a joiningoperation (e.g., during a welding operation), or both.

Another aspect of the invention contemplates a method for post-consumerreclamation, recycling, or both of parts made using the presentinvention. One approach envisions providing a part having the compositestructure taught herein, and subjecting it to a step of separatinghydrocarbon compounds (e.g., by an elevated temperature heating step)from the metallic materials. Either or both of the hydrocarbon compoundsor the metallic materials can be recovered and re-used. Another approachenvisions recycling by grinding the composite material or otherwiseforming particles from the composite materials, and optionally providingthe particles as an ingredient for the core material of a composite(such as a composite material described herein).

It should be appreciated that the compositions of the following examplesmay be varied by about ±20% and give similar results (e.g., within about±20%). Further, other materials taught herein may be substituted forthose stated and similar results are contemplated.

EXAMPLES Example 1

A filled thermoplastic material is prepared by mixing about 15 volume %low carbon steel fibers having a diameter from about 4 to about 40 μm,and a length from about 1 to about 10 mm and about 85 volume % of acopolyamide of about 50 wt. % nylon 6 and about 50 wt. % nylon 6,9 (thecopolymer characterized by an elastic modulus of about 300 MPa measuredaccording to ISO 527-2, a melting point of about 130° C. as measuredaccording to ISO 11357, and an elongation at break of about 900%measured according to ISO 527-3). The filled thermoplastic material ismixed at a temperature from about 190° C. to about 250° C. The filledthermoplastic material is then placed between two sheets of low carbonsteel, each having a thickness of about 0.2 mm. The materials are thenpressed at a temperature from about 200° C. to about 230° C. with apressure of about 1 to about 22 MPa. The composite material has a corethickness of the filled thermoplastic material of about 0.4 mm. Thecomposite material is stamped in a high speed stamping operation with adraw ratio greater than about 3, and no cracks or other surface defectsare observed. After stamping, the surface of the composite material isrelatively smooth compared to the surface of a monolithic low carbonsteel sample having the same total thickness and stamped under the sameconditions. The composite material is then submitted to a typical e-coatprocess and painted with a primer and black paint. The painted surfacehas a smooth finish with no pitting, no orange peeling, and no othervisible surface defects. The painted surface is characterized as a classA finish. The surface of the painted composite material is smoother thanthe surface of a similarly processed monolithic sample of low carbonsteel having a thickness of about 0.8 mm.

Example 2

A composite material is prepared using the same materials, composition,and method as Example 1, except the fibers are replaced with low carbonfibers having a generally rectangular cross-section in the directiontransverse to the length of the fibers. The fibers have an averagelength of about 2.3 mm. The average cross-sectional area of the fibersis about 0.0045 mm². The ratio of the width to the thickness of thefibers is about 2 to 8. The composite material has a thickness of about0.8 mm. The composite material is stacked with a sample of cold rolledsteel having a thickness of about 0.8 mm. The stack is placed in a spotwelding machine between a pair of weld tips having a diameter of about13 mm. A force of about 2.2 kNt is applied to the weld tips. Theresistivity of the composite material in the through-thickness directionis determined while under force of 2.2 kNt. Thus determined, theelectrical resistivity of Example 2 composite material is about 0.1 Ω·cmor less. When welded using weld schedules typical for two sheets of coldrolled steel having a thickness of about 0.8 mm, the composite materialwelds to the cold rolled steel, producing a weld nugget having adiameter greater than the diameter of the weld tips. No extra heating,no extra weld cycles, and no extra current are required to produce agood weld with Example 2.

Example 3

A composite material is prepared using the same materials, composition,and method as Example 1, except the metal sheets are replaced by 0.2 mmthick sheets of a high strength steel having a yield strength of about350 MPa, a tensile strength of about 460 MPa, and an elongation of about22%. The composite material is expected to have a yield strength ofabout 193 MPa, a tensile strength of about 253 MPa, and an elongation ofabout 22%. The density of the composite material is calculated to beabout 34% less than a monolithic sheet of the low carbon steel havingthe same thickness (about 0.8 mm). The composite material is calculatedhave a yield strength that is about 50 MPa or more higher than the yieldstrength of the monolithic sheet of low carbon steel having the samethickness. The composite material is calculated to have a tensilestrength that is at least about 90% of the tensile strength of themonolithic sheet of low carbon steel having the same thickness. Thecomposite material is calculated to have a flexural modulus that is atleast about 85% of the flexural modulus of the monolithic sheet of lowcarbon steel having the same thickness.

Other examples within the scope of the teachings are illustrated inparagraphs 126-133 and 138-154 and Tables 1-4 (examples 1-4, 8-26,28-31, and 33-34) of International Patent Application Publication No. WO2010/021899, and paragraphs 114-117, and 119-127 and 129 (examples 1-4,6-10, and 11A) and FIGS. 2A, 2B, 2C, 2D, 2E, 2F, 2G, 2H, 2I, 2J, 3, 4,5, 6, 7, 8, 9A, and 9B of U.S. patent application Ser. No. 12/978,974(filed on Dec. 27, 2010), both incorporated herein by reference.

As used herein, unless otherwise stated, the teachings envision that anymember of a genus (list) may be excluded from the genus; and/or anymember of a Markush grouping may be excluded from the grouping.

Unless otherwise stated, any numerical values recited herein include allvalues from the lower value to the upper value in increments of one unitprovided that there is a separation of at least 2 units between anylower value and any higher value. As an example, if it is stated thatthe amount of a component, a property, or a value of a process variablesuch as, for example, temperature, pressure, time and the like is, forexample, from 1 to 90, preferably from 20 to 80, more preferably from 30to 70, it is intended that intermediate range values such as (forexample, 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.) are within theteachings of this specification. Likewise, individual intermediatevalues are also within the present teachings. For values which are lessthan one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 asappropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to be considered to beexpressly stated in this application in a similar manner. As can beseen, the teaching of amounts expressed as “parts by weight” herein alsocontemplates the same ranges expressed in terms of percent by weight.Thus, an expression in the Detailed Description of the Invention of arange in terms of at “‘x’ parts by weight of the resulting polymericblend composition” also contemplates a teaching of ranges of samerecited amount of “x” in percent by weight of the resulting polymericblend composition.”

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes. The term “consisting essentially of” to describe a combinationshall include the elements. Ingredients, components or steps identified,and such other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations of elements, ingredients, components or stepsherein also contemplates embodiments that consist essentially of, oreven consist of the elements, ingredients, components or steps.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps. All references herein to elements ormetals belonging to a certain Group refer to the Periodic Table of theElements published and copyrighted by CRC Press, Inc., 1989. Anyreference to the Group or Groups shall be to the Group or Groups asreflected in this Periodic Table of the Elements using the IUPAC systemfor numbering groups.

As used herein the terms “polymer” and “polymerization” are generic, andcan include either or both of the more specific cases of “homo-” andcopolymer” and “homo- and copolymerization”, respectively.

It is understood that the above description is intended to beillustrative and not restrictive. Many embodiments as well as manyapplications besides the examples provided will be apparent to those ofskill in the art upon reading the above description. The scope of theinvention should, therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent applications and publications, areincorporated by reference for all purposes. The omission in thefollowing claims of any aspect of subject matter that is disclosedherein is not a disclaimer of such subject matter, nor should it beregarded that the inventors did not consider such subject matter to bepart of the disclosed inventive subject matter.

What is claimed is:
 1. A light weight composite comprising: a firstmetallic layer; a second metallic layer; and an extruded sheet of afilled polymeric material having a thickness interposed between thefirst metallic layer and the second metallic layer, wherein the filledpolymeric materials comprises: i. one or more polymers including apolyolefin polymer having a crystallinity of about 10 wt. % to about 80wt. % as measured using differential scanning calorimetry and a meltingpoint greater than about 80° C., as measured according to ASTM D3418-08;and ii. greater than 5 volume percent and less than 25 volume percentbased on the total volume of the filled polymeric material of a mass ofmetallic fibers distributed within the one or more polymers the massspanning the thickness of the sheet and including fibers having agenerally rectangular cross-section in a direction perpendicular to alength of the fiber, a weight average length greater than about 200 μmand less than about 25 mm, wherein the weight ratio of the one or morepolymers to the metallic fibers is greater than about 2.2:1; the lightweight composite has a weld current range of about 1.5 kA or more; andthe light weight composite is capable of being stamped to a draw ratiogreater than 1.5.
 2. The light weight composite of claim 1, wherein thepolyolefin polymer includes more than one α-olefins.
 3. The light weightcomposite of claim 1, wherein the fraction by number of the metallicfibers spanning the thickness of the extruded sheet is about 0.10 orless.
 4. The light weight composite of claim 1, wherein an edge of thelight weight composite is sealed.
 5. The light weight composite of claim4, wherein the sealed edge includes a weld joining the first and secondmetal layers.
 6. An article including the light weight composite ofclaim 4; a metal component; and a weld joint connecting the light weightcomposite to the metal component.
 7. The article of claim 6, wherein theweld joint is formed by laser welding.
 8. A process of forming thearticle of claim 6 comprising the steps of: stamping the light weightcomposite including drawing at least one portion of the light weightcomposite by a draw ratio greater than 1.5; and welding the light weightcomposite to the metal component, wherein the welding step includeslaser welding.
 9. The light weight composite of claim 1, wherein theextruded sheet of the filled polymeric material has edges and the lightweight composite includes a coating or protective layer over one or moreof the edges.
 10. The light weight composite of claim 9, wherein thecoating or protective layer substantially protects the edge from contactwith a liquid or gas.
 11. The light weight composite of claim 9, whereinthe coating or protective layer has a lower permeability to moisturerelative to the filled polymeric material.
 12. The light weightcomposite of claim 1, wherein the one or more polymers has a melt indexsufficiently high so that the polymer can be processed using extrusionequipment; and the concentration of pores and voids in the filledpolymeric material is from 0 to about 5 volume %, based on the totalvolume of the filled polymeric material.
 13. The light weight compositeof claim 12, wherein the volume of the filled polymeric material is 30volume % to 92% of the total volume of the light weight composite, thetotal thickness of the first and second metallic layers is from 5% to70% of the total thickness of the light weight composite; and thepolyolefin polymer includes a polyethylene copolymer having at least 60%ethylene, a number average molecular weight greater than 20,000 andconsists entirely of one or more α-olefins.
 14. The light weightcomposite of claim 13, wherein the light composite has a thickness of0.3 mm or more and the filled polymeric material has a generally uniformthickness that is 40% or more of the total thickness of the compositematerial.
 15. A stamped and welded article including the light weightcomposite of claim 1 welded to a sheet of steel, and including at leastone weld nugget joining the sheet of steel and the light weightcomposite; and wherein the light weight composite is stamped to a drawratio greater than 1.5.
 16. The article of claim 15, wherein the firstmetallic layer has a thickness from about 0.10 mm to about 1.5 mm; thesecond metallic layer has a thickness from about 0.10 mm to about 1.5mm; the volume of the filled polymeric material is 30 volume % to 92% ofthe total volume of the light weight composite; the total thickness ofthe first and second metallic sheets is from 5% to 70% of the totalthickness of the light weight composite; the one or more polymers ispresent at a concentration of about 75 volume percent or more, based onthe total volume of the filled polymeric material, and the first andsecond metallic layers are formed of steel sheets and the metallicfibers includes steel fibers.
 17. The article of claim 16, wherein thelight weight composite includes area contact between a steel fiber and asteel layer, area contact between two steel fibers, or both.
 18. Thearticle of claim 15, wherein the polyolefin polymer includes more thanone α-olefins monomers; the one or more polymers has a melt indexsufficiently high so that the polymer can be processed using extrusionequipment; and the concentration of pores and voids in the filledpolymeric material is from 0 to about 5 volume %, based on the totalvolume of the filled polymeric material; the volume of the filledpolymeric material is 30 volume % to 92% of the total volume of thelight weight composite, the total thickness of the first and secondmetallic layers is from 5% to 70% of the total thickness of the lightweight composite; and the light composite has a thickness of 0.3 mm ormore and the filled polymeric material has a generally uniform thicknessthat is 40% or more of the total thickness of the composite material.19. The article of claim 15, wherein the polyolefin is a copolymerincluding at least 60 wt. % of an α-olefin and at least one additionalmonomer and the polyolefin is a low density polyethylene, a linear lowdensity polyethylene, a very low density polyethylene, a polyethyleneplastomer, or any combination thereof.
 20. A process of forming acomposite part comprising a step of stamping the light weight compositeof claim 1, includes a step of drawing at least one portion of the lightweight composite by a draw ratio greater than 1.5.
 21. The process ofclaim 20, wherein the process includes a step of welding the lightweight composite to at least one additional metal containing material,wherein the welding step includes laser welding.